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9.4.2013 Official
Journal
of
the
European
Union L
100/1
II
(Non-legislative acts)
DECISIONS
COMMISSION IMPLEMENTING DECISION
of 26 March 2013
establishing the best available techniques (BAT) conclusions under Directive 2010/75/EU of the
European Parliament and of the Council on industrial emissions for the production of cement,
lime and magnesium oxide
(notified under document C(2013) 1728)
(Text with EEA relevance)
(2013/163/EU)
THE EUROPEAN COMMISSION,
with the best available techniques, associated monitoring,
associated consumption levels and, where appropriate,
Having regard to the Treaty on the Functioning of the European
relevant site remediation measures.
Union,
Having regard to Directive 2010/75/EU of the European
(4) In
accordance with Article 14(3) of Directive
Parliament and of the Council of 24 November 2010 on
2010/75/EU, BAT conclusions are to be the reference
industrial emissions (integrated pollution prevention and
for setting permit conditions for installations covered
control) ( 1 ), and in particular Article 13(5) thereof,
by Chapter II of that Directive.
Whereas:
(5) Article
15(3)
of
Directive
2010/75/EU
requires
the
(1) Article
13(1)
of
Directive
2010/75/EU
requires
the
competent authority to set emission limit values that
Commission to organise an exchange of information
ensure that, under normal operating conditions,
on industrial emissions between it and Member States,
emissions do not exceed the emission levels associated
the industries concerned and non-governmental organi
with the best available techniques as laid down in the
sations promoting environmental protection in order to
decisions on BAT conclusions referred to in Article 13(5)
facilitate the drawing up of best available techniques
of Directive 2010/75/EU.
(BAT) reference documents as defined in Article 3(11)
of that Directive.
(6) Article
15(4)
of
Directive
2010/75/EU
provides
for
dero
gations from the requirement laid down in Article 15(3)
(2) In
accordance with Article 13(2) of Directive
2010/75/EU, the exchange of information is to address
only where the costs associated with the achievement of
the performance of installations and techniques in terms
the emission levels associated with the BAT dispropor
of emissions, expressed as short- and long-term averages,
tionately outweigh the environmental benefits due to the
where appropriate, and the associated reference
geographical location, the local environmental conditions
conditions, consumption and nature of raw materials,
or the technical characteristics of the installation
water consumption, use of energy and generation of
concerned.
waste and the techniques used, associated monitoring,
cross-media effects, economic and technical viability
(7) Article
16(1)
of
Directive
2010/75/EU
provides
that
the
and developments therein and best available techniques
monitoring requirements in the permit referred to in
and emerging techniques identified after considering the
point (c) of Article 14(1) of the Directive are to be
issues mentioned in points (a) and (b) of Article 13(2) of
based on the conclusions on monitoring as described
that Directive.
in the BAT conclusions.
(3)
‘BAT conclusions’ as defined in Article 3(12) of Directive
2010/75/EU are the key element of BAT reference
(8) In
accordance with Article 21(3) of Directive
documents and lay down the conclusions on best
2010/75/EU, within 4 years of publication of decisions
available techniques, their description, information to
on BAT conclusions, the competent authority is to
assess their applicability, the emission levels associated
reconsider and, if necessary, update all the permit
conditions and ensure that the installation complies
( 1 ) OJ L 334, 17.12.2010, p. 17.
with those permit conditions.

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L 100/2
EN
Official Journal of the European Union
9.4.2013
(9) Commission
Decision
of
16
May
2011
establishing
a HAS ADOPTED THIS DECISION:
forum for the exchange of information pursuant to
Article 13 of Directive 2010/75/EU on industrial
Article 1
emissions ( 1 ) established a forum composed of represen
The BAT conclusions for the production of cement, lime and
tatives of Member States, the industries concerned and
magnesium oxide are set out in the Annex to this Decision.
non-governmental organisations promoting environ
mental protection.
Article 2
(10) In accordance with Article 13(4) of Directive
This Decision is addressed to the Member States.
2010/75/EU, the Commission obtained the opinion ( 2 )
of that forum on the proposed content of the BAT
reference document for the production of cement, lime
Done at Brussels, 26 March 2013.
and magnesium oxide on 13 September 2012 and made
it publicly available.
For the Commission
(11) The
measures provided for in this Decision are in
accordance with the opinion of the Committee estab
Janez POTONIK
lished by Article 75(1) of Directive 2010/75/EU,
Member of the Commission
( 1 ) OJ C 146, 17.5.2011, p. 3.
( 2 ) http://circa.europa.eu/Public/irc/env/ied/library?l=/ied_art_13_forum/
opinions_article

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EN
9.4.2013 Official
Journal
of
the
European
Union L
100/3
ANNEX
BAT CONCLUSIONS FOR THE PRODUCTION OF CEMENT, LIME AND MAGNESIUM OXIDE
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
NOTE ON THE EXCHANGE OF INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
GENERAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
BAT CONCLUSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.1
General BAT conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.1.1 Environmental management systems (EMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.1.2 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
1.2
BAT conclusions for the cement industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
1.2.1 General primary techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
1.2.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
1.2.3 Energy consumption and process selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
1.2.4 Use of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
1.2.5 Dust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
1.2.6 Gaseous compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
1.2.7 PCDD/F emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
1.2.8 Metal emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
1.2.9 Process losses/waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
1.3
BAT conclusions for the lime industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
1.3.1 General primary techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
1.3.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
1.3.3 Energy consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
1.3.4 Consumption of limestone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
1.3.5 Selection of fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
1.3.6 Dust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
1.3.7 Gaseous compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
1.3.8 PCDD/F emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
1.3.9 Metal emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
1.3.10 Process losses/waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34

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L 100/4
EN
Official Journal of the European Union
9.4.2013
1.4
BAT conclusions for the magnesium oxide industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
1.4.1 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
1.4.2 Energy consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
1.4.3 Dust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
1.4.4 Gaseous compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
1.4.5 Process losses/waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
1.4.6 Use of wastes as fuels and/or raw materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
DESCRIPTION OF TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
1.5
Description of techniques for the cement industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5.1 Dust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
1.5.2 NOx emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
1.5.3 SOx emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
1.6
Description of techniques for lime industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
1.6.1 Dust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
1.6.2 NOx emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
1.6.3 SOx emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
1.7
Description of techniques for the magnesia industry (dry process route) . . . . . . . . . . . . . . . . . . . . .
44
1.7.1 Dust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
1.7.2 SOx emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45

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EN
9.4.2013 Official
Journal
of
the
European
Union L
100/5
SCOPE
These BAT conclusions concern the following industrial activities specified in Section 3.1 of Annex I to Directive
2010/75/EU, namely:
'3.1. Production of cement, lime and magnesium oxide', which involve:
(a) production of cement clinker in rotary kilns with a production capacity exceeding 500 tonnes per day or in
other kilns with a production capacity exceeding 50 tonnes per day;
(b) production of lime in kilns with a production capacity exceeding 50 tonnes per day;
(c) production of magnesium oxide in kilns with a production capacity exceeding 50 tonnes per day.
Regarding point 3.1(c) above, these BAT conclusions only address the production of MgO using the dry process route
based on mined natural magnesite (magnesium carbonate - MgCO 3 ).
In particular, concerning the above-mentioned activities, these BAT conclusions cover the following:
— production of cement, lime and magnesium oxide (dry process route)
— raw materials – storage and preparation
— fuels – storage and preparation
— use of waste as raw materials and/or fuels – quality requirements, control and preparation
— products – storage and preparation
— packaging and dispatch.
These BAT conclusions do not address the following activities:
— the production of magnesium oxide using the wet process route using magnesium chloride as the starting material,
covered by the Reference Document on Best Available Techniques for Large Volume Inorganic Chemicals – Solids and
Others Industry (LVIC-S)
— the production of ultra low-carbon dolime (i.e. a mixture of calcium and magnesium oxides produced by the nearly
full decarbonation of dolomite (CaCO 3 .MgCO 3 ). The residual CO 2 content of the product is below 0,25 % and the
bulk density well below 3,05 g/cm 3 )
— shaft kilns for cement clinker production
— activities which are not directly associated with the primary activity such as quarrying.
Other reference documents which are of relevance for the activities covered by these BAT conclusions are the following:
Reference documents Activity
Emissions from Storage (EFS)
Storage and handling of raw materials and products
General Principles of Monitoring (MON) Emissions
monitoring
Waste Treatments Industries (WT) Waste
treatment
Energy Efficiency (ENE) General
energy
efficiency
Economic and Cross-media Effects (ECM) Economics
and
cross-media
effects
of
techniques

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L 100/6
EN
Official Journal of the European Union
9.4.2013
The techniques listed and described in these BAT conclusions are neither prescriptive nor exhaustive. Other techniques
may be used that ensure at least an equivalent level of environmental protection.
Where these BAT conclusions address waste co-incineration plants, this is without prejudice to the provisions of Chapter
IV of and Annex VI to Directive 2010/75/EU.
Where these BAT conclusions address energy efficiency, this is without prejudice to the provisions of the new Directive
2012/27/EU of the European Parliament and of the Council ( 1 ) on Energy Efficiency.
NOTE ON THE EXCHANGE OF INFORMATION
The exchange of information on BAT for the Cement, Lime and Magnesium Oxide sectors ended in 2008. The
information available then, complemented by additional information concerning the emissions from magnesium oxide
production, was used for reaching these BAT conclusions.
DEFINITIONS
For the purposes of these BAT conclusions, the following definitions apply:
Term used Definition
New plant
A plant introduced on the site of the installation following the
publication of these BAT conclusions or a complete replacement of a
plant on the existing foundations of the installation following the
publication of these BAT conclusions
Existing plant A
plant
which
is
not
a
new
plant
Major upgrade An
upgrade
of
the
plant/kiln
involving
a
major
change
in
the
kiln
requirements or technology, or replacement of the kiln
'Use of waste as fuel and/or raw material' The
term
covers
the
use
of:
— waste fuels with significant calorific value; and
— waste materials without significant calorific value but with mineral
components used as raw materials that contribute to the inter
mediate product clinker; and
— waste materials that have both a significant calorific value and
mineral components
Definition for certain products
Term used Definition
White cement Cement
falling
under
the
following
PRODCOM
2007
code:
26.51.12.10
– White Portland cement
Special cement Special
cements
falling
under
the
following
PRODCOM
2007
codes:
— 26.51.12.50 – Aluminous cement
— 26.51.12.90 – Other hydraulic cements
Dolime or calcinated dolime A
mixture
of
calcium
and
magnesium
oxides
produced
by
the
decar
bonation of dolomite (CaCO 3 .MgCO 3 ) with a residual CO 2 content of
the product exceeding 0,25 % and the bulk density of the commercial
product well below 3,05 g/cm 3 . The free content as MgO is usually
between 25 % and 40 %.
Sintered dolime A
mixture
of
calcium
and
magnesium
oxides
used
solely
for
the
production of refractory bricks and other refractory products, with a
minimum bulk density of 3,05 g/cm 3
( 1 ) OJ L 315, 14.11.2012, p. 1.

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Definition for certain air pollutants
Term used Definition
NO x expressed as NO 2
The sum of nitrogen oxide (NO) and nitrogen dioxide (NO 2 ) expressed
as NO 2
SO x expressed as SO 2
The sum of sulphur dioxide (SO 2 ) and sulphur trioxide (SO 3 ) expressed
as SO 2
Hydrogen chloride expressed as HCl All
gaseous
chlorides
expressed
as
HCl
Hydrogen fluoride expressed as HF All
gaseous
fluorides
expressed
as
HF
Abbreviations
ASK Annular
shaft
kiln
DBM Dead
burned
magnesia
I-TEQ International
toxicity
equivalent
LRK Long
rotary
kiln
MFSK Mixed
feed
shaft
kiln
OK Other
kilns
For the lime industry this covers:
— double-inclined shaft kilns
— multi-chamber shaft kilns
— central burner shaft kilns
— external chamber shaft kilns
— beam burner shaft kilns
— internal arch shaft kilns
— travelling grate kilns
— ‘top-shaped’ kilns
— flash calciner kilns
— rotating hearth kilns
OSK Other
shaft
kiln
(shaft
kilns
other
than
ASK
and
MFSK)
PCDD Polychlorinated
dibenzo-p-dioxin
PCDF Polychlorinated
dibenzofuran
PFRK Parallel
flow
regenerative
kiln
PRK Rotary
kiln
with
preheater
GENERAL CONSIDERATIONS
Averaging periods and reference conditions for air emissions
Emission levels associated with the best available techniques (BAT-AELs) given in these BAT conclusions refer to standard
conditions: dry gas at a temperature of 273 K, and a pressure of 1 013 hPa.

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L 100/8
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Official Journal of the European Union
9.4.2013
Values given in concentrations apply under the following reference conditions:
Activities Reference
conditions
Kiln activities Cement
industry 10
%
oxygen
by
volume
Lime industry ( 1 ) 11
%
oxygen
by
volume
Magnesium oxide industry (dry process
10 % oxygen by volume
route) ( 2 )
Non-kiln activities All
processes No
correction
for
oxygen
Lime hydrating plants As
emitted
(no correction for oxygen and for dry gas)
( 1 ) For sintered dolime produced by the 'double-pass process', the correction for oxygen does not apply.
( 2 ) For dead burned magnesia (DBM) produced by the 'double-pass process', the correction for oxygen does not apply.
For averaging periods the following definitions apply:
Daily average value Average
value
over
a
period
of
24
hours
measured
by
the
continuous monitoring of emissions
Average over the sampling period
Average value of spot measurements (periodic) of at least
30 minutes each, unless otherwise stated
Conversion to reference oxygen concentration
The formula for calculating the emissions concentration at a reference oxygen level is shown below:
21 – O
E

R

R 21 – O M E M
Where:
E R (mg/Nm 3 ): emissions
concentration
related
to
the
reference
oxygen
level
O R
O R (vol %):
reference oxygen level
E M (mg/Nm 3 ): emissions concentration related to the measured oxygen level O M
O M (vol %):
measured oxygen level
BAT CONCLUSIONS
1.1 General BAT conclusions
The BAT mentioned in this section apply to all installations covered by these BAT conclusions (cement, lime and
magnesium oxide industry).
The process-specific BAT included in Sections 1.2 - 1.4 apply in addition to the general BAT mentioned in this section.
1.1.1 Environmental management systems (EMS)
1. In
order
to
improve
the
overall
environmental
performance
of
the
plants/installations
producing
cement,
lime
and
magnesium oxide, production BAT is to implement and adhere to an environmental management system (EMS) that
incorporates all of the following features:
i. commitment of the management, including senior management;
ii. definition of an environmental policy that includes the continuous improvement of the installation by the
management;

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iii. planning and establishing the necessary procedures, objectives and targets, in conjunction with financial planning and
investment;
iv. implementation of procedures paying particular attention to:
(a) structure and responsibility
(b) training, awareness and competence
(c) communication
(d) employee involvement
(e) documentation
(f) efficient process control
(g) maintenance programmes
(h) emergency preparedness and response
(i) safeguarding compliance with environmental legislation;
v. checking performance and taking corrective action, paying particular attention to:
(a) monitoring and measurement (see also the Reference Document on the General Principles of Monitoring)
(b) corrective and preventive action
(c) maintenance of records
(d) independent (where practicable) internal and external auditing in order to determine whether or not the EMS
conforms to planned arrangements and has been properly implemented and maintained;
vi. review of the EMS and its continuing suitability, adequacy and effectiveness by senior management;
vii. following the development of cleaner technologies;
viii. consideration for the environmental impacts from the eventual decommissioning of the installation at the stage of
designing a new plant, and throughout its operating life;
ix. application of sectoral benchmarking on a regular basis.
Applicability
The scope (e.g. level of details) and nature of the EMS (e.g. standardised or non-standardised) will generally be related to
the nature, scale and complexity of the installation, and the range of environmental impacts it may have.
1.1.2 Noise
2. In
order
to
reduce/minimise
noise
emissions
during
the
manufacturing
processes
for
cement,
lime
and
magnesium
oxide, BAT is to use a combination of the following techniques:
Technique
a Select
an
appropriate
location
for
noisy
operations
b Enclose
noisy
operations/units

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L 100/10
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Official Journal of the European Union
9.4.2013
Technique
c Use
vibration
insulation
of
operations/units
d Use
internal
and
external
lining
made
of
impact-absorbent
material
e Use
soundproofed
buildings
to
shelter
any
noisy
operations
involving
material
transformation
equipment
f Use
noise
protection
walls
and/or
natural
noise
barriers
g Use
outlet
silencers
to
exhaust
stacks
h Lag
ducts
and
final
blowers
which
are
situated
in
soundproofed
buildings
i Close
doors
and
windows
of
covered
areas
j Use
sound
insulation
of
machine
buildings
k
Use sound insulation of wall breaks, e.g. by installation of a sluice at the entrance point of a belt conveyor
l
Install sound absorbers at air outlets, e.g. the clean gas outlet of dedusting units
m Reduce
flow
rates
in
ducts
n Use
sound
insulation
of
ducts
o
Apply the decoupled arrangement of noise sources and potentially resonant components, e.g. of compressors
and ducts
p Use
silencers
for
filter
fans
q Use
soundproofed
modules
for
technical
devices
(e.g.
compressors)
r Use
rubber
shields
for
mills
(avoiding
the
contact
of
metal
against
metal)
s
Construct buildings or growing trees and bushes between the protected area and the noisy activity
1.2 BAT conclusions for the cement industry
Unless otherwise stated, the BAT conclusions presented in this section can be applied to all installations in the cement
industry.
1.2.1 General primary techniques
3. In order to reduce emissions from the kiln and use energy efficiently, BAT is to achieve a smooth and stable kiln
process, operating close to the process parameter set points by using the following techniques:
Technique
a Process
control
optimisation,
including
computer-based
automatic
control
b Using
modern,
gravimetric
solid
fuel
feed
systems
4. In order to prevent and/or reduce emissions, BAT is to carry out a careful selection and control of all substances
entering the kiln.

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EN
9.4.2013 Official
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European
Union L
100/11
Description
Careful selection and control of substances entering the kiln can reduce emissions. The chemical composition of the
substances and the way they are fed in the kiln are factors that should be taken into account during the selection.
Substances of concern may include the substances mentioned in BAT 11 and in BAT 24 to 28.
1.2.2 Monitoring
5. BAT is to carry out the monitoring and measurements of process parameters and emissions on a regular basis and
to monitor emissions in accordance with the relevant EN standards or, if EN standards are not available, ISO, national or
other international standards that ensure the provision of data of an equivalent scientific quality, including the following:
Technique Applicability
a Continuous
measurements
of
process
parameters
Generally applicable
demonstrating the process stability, such as
temperature, O 2 content, pressure and flowrate
b Monitoring
and
stabilising
critical
process
parameters,
Generally applicable
i.e. homogenous raw material mix and fuel feed,
regular dosage and excess oxygen
c Continuous
measurements
of
NH 3 emissions when Generally applicable
SNCR is applied
d Continuous
measurements
of
dust,
NO x , SO x , and CO Applicable to kiln processes
emissions
e Periodic
measurements
of
PCDD/F
and
metal
emissions
f Continuous
or
periodic
measurements
of
HCl,
HF
and
TOC emissions.
g Continuous
or
periodic
measurements
of
dust Applicable
to
non-kiln
activities.
For small sources (< 10 000 Nm 3 /h) from dusty oper
ations other than cooling and the main milling
processes, the frequency of measurements or
performance checks should be based on a maintenance
management system.
Description
The selection between continuous or periodic measurements mentioned in BAT 5(f) is based on the emission source and
the type of pollutant expected.
1.2.3 Energy consumption and process selection
1.2.3.1 P r o c e s s s e l e c t i o n
6. In order to reduce energy consumption, BAT is to use a dry process kiln with multistage preheating and precal
cination.
Description
In this type of kiln system, exhaust gases and recovered waste heat from the cooler can be used to preheat and precalcine
the raw material feed before entering the kiln, providing significant savings in energy consumption.
Applicability
Applicable to new plants and major upgrades, subject to raw materials moisture content.
BAT-associated energy consumption levels
See Table 1.

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L 100/12
EN
Official Journal of the European Union
9.4.2013
Table 1
BAT-associated energy consumption levels for new plants and major upgrades using dry process kiln with
multistage preheating and precalcination
Process Unit
BAT-associated energy consumption
levels ( 1 )
Dry process with multistage preheating
MJ/tonne clinker 2
900
–
3
300
( 2 ) ( 3 )
and precalcination
( 1 ) Levels do not apply to plants producing special cement or white cement clinker that require significantly higher process temperatures
due to product specifications.
( 2 ) Under normal (excluding, e.g. start-ups and shutdowns) and optimised operational conditions.
( 3 ) The production capacity has an influence on the energy demand, with higher capacities providing energy savings and smaller capacities
requiring more energy. Energy consumption also depends on the number of cyclone preheater stages, with more cyclone preheater
stages leading to lower energy consumption of the kiln process. The appropriate number of cyclone preheater stages is mainly
determined by the moisture content of raw materials.
1.2.3.2 E n e r g y c o n s u m p t i o n
7. In order to reduce/minimise thermal energy consumption, BAT is to use a combination of the following techniques:
Technique Applicability
a Applying
improved
and
optimised
kiln
systems
and
a
Generally applicable. For existing kilns, the applicability
smooth and stable kiln process, operating close to the of preheating and precalcination is subject to the kiln
process parameter set points by applying:
system configuration
I. process control optimisation, including computer-
based automatic control systems
II. modern, gravimetric solid fuel feed systems
III. preheating and precalcination to the extent
possible, considering the existing kiln system
configuration
b Recovering
excess
heat
from
kilns,
especially
from
Generally applicable in the cement industry.
their cooling zone. In particular, the kiln excess heat
from the cooling zone (hot air) or from the preheater Recovery of excess heat from the cooling zone is
can be used for drying raw materials
applicable when grate coolers are used.
Limited recovery efficiency can be achieved on rotary
coolers
c Applying
the
appropriate
number
of
cyclone
stages
Cyclone preheater stages are applicable to new plants
related to the characteristics and properties of raw and major upgrades.
material and fuels used
d Using
fuels
with
characteristics
which
have
a
positive
The technique is generally applicable to the cement
influence on the thermal energy consumption
kilns subject to fuel availability and for existing kilns
subject to the technical possibilities of injecting the fuel
into the kiln
e When
replacing
conventional
fuels
by
waste
fuels,
Generally applicable to all cement kiln types
using optimised and suitable cement kiln systems
for burning wastes
f Minimising
bypass
flows Generally
applicable
to
the
cement
industry
Description
Several factors affect the energy consumption of modern kiln systems such as raw materials properties (e.g. moisture
content, burnability), the use of fuels, with different properties, as well as the use of a gas bypass system. Furthermore, the
production capacity of the kiln has an influence on the energy demand.

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EN
9.4.2013 Official
Journal
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the
European
Union L
100/13
Technique 7c: the appropriate number of cyclone stages for preheating is determined by the throughput and the moisture
content of raw materials and fuels which have to be dried by the remaining flue-gas heat because local raw materials vary
widely regarding their moisture content or burnability
Technique 7d: conventional and waste fuels can be used in the cement industry. The characteristics of the fuels used, such
as adequate calorific value and low moisture content, have a positive influence on the specific energy consumption of the
kiln.
Technique 7f: the removal of hot raw material and hot gas leads to a higher specific energy consumption of about 6 –
12 MJ/tonne clinker per percentage point of removed kiln inlet gas. Hence, minimising the use of gas bypass has a
positive effect on energy consumption.
8. In order to reduce primary energy consumption, BAT is to consider the reduction of the clinker content of cement
and cement products.
Description
The reduction of the clinker content of cement and cement products can be achieved by adding fillers and/or additions,
such as blast furnace slag, limestone, fly ash and pozzolana in the grinding step in accordance with the relevant cement
standards.
Applicability
Generally applicable to the cement industry, subject to (local) availability of fillers and/or additions and local market
specificities.
9. In order to reduce primary energy consumption, BAT is to consider cogeneration/combined heat and power plants.
Description
The employment of cogeneration plants for the production of steam and electricity or combined heat and power plants
can be applied in the cement industry by recovering waste heat from the clinker cooler or kiln flue-gases using the
conventional steam cycle processes or other techniques. Furthermore, excess heat can be recovered from the clinker
cooler or kiln flue-gases for district heating or industrial applications.
Applicability
The technique is applicable in all cement kilns if sufficient excess heat is available, if appropriate process parameters can
be met, and if economic viability is ensured.
10. In
order
to
reduce/minimise
electrical
energy
consumption,
BAT
is
to
use
one
or
a
combination
of
the
following
techniques:
Technique
a Using
power
management
systems
b Using
grinding
equipment
and
other
electricity
based
equipment
with
high
energy
efficiency
c Using
improved
monitoring
systems
d Reducing
air
leaks
into
the
system
e Process
control
optimisation
1.2.4 Use of waste
1.2.4.1 W a s t e q u a l i t y c o n t r o l
11.
In order to guarantee the characteristics of the wastes to be used as fuels and/or raw materials in a cement kiln and
reduce emissions, BAT is to apply the following techniques:

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L 100/14
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Official Journal of the European Union
9.4.2013
Technique
a
Apply quality assurance systems to guarantee the characteristics of wastes and to analyse any waste that is to be
used as raw material and/or fuel in a cement kiln for:
I. constant quality
II. physical criteria, e.g. emissions formation, coarseness, reactivity, burnability, calorific value
III. chemical criteria, e.g. chlorine, sulphur, alkali and phosphate content and relevant metals content
b
Control the amount of relevant parameters for any waste that is to be used as raw material and/or fuel in a
cement kiln, such as chlorine, relevant metals (e.g. cadmium, mercury, thallium), sulphur, total halogen content
c Apply
quality
assurance
systems
for
each
waste
load
Description
Different types of waste materials can replace primary raw materials and/or fossil fuels in cement manufacturing and will
contribute to saving natural resources.
1.2.4.2 W a s t e f e e d i n g i n t o t h e k i l n
12. In order to ensure appropriate treatment of the wastes used as fuel and/or raw materials in the kiln, BAT is to use
the following techniques:
Technique
a Use
appropriate
points
to
feed
the
waste
into
the
kiln
in
terms
of
temperature
and
residence
time
depending
on
kiln design and kiln operation
b To
feed
waste
materials
containing
organic
components
that
can
be
volatilised
before
the
calcining
zone
into
the
adequately high temperature zones of the kiln system
c To
operate
in
such
a
way
that
the
gas
resulting
from
the
co-incineration
of
waste
is
raised
in
a
controlled
and
homogeneous fashion, even under the most unfavourable conditions, to a temperature of 850 °C for 2 seconds
d To
raise
the
temperature
to
1
100
°C,
if
hazardous
waste
with
a
content
of
more
than
1
%
of
halogenated
organic substances, expressed as chlorine, are co-incinerated
e To
feed
wastes
continuously
and
constantly
f Delay
or
stop
co-incinerating
waste
for
operations
such
as
start-ups
and/or
shutdowns
when
appropriate
temperatures and residence times cannot be reached, as noted in a) to d) above
1.2.4.3 S a f e t y m a n a g e m e n t f o r t h e u s e o f h a z a r d o u s w a s t e m a t e r i a l s
13. BAT is to apply safety management for the storage, handling and feeding of hazardous waste materials, such as
using a risk-based approach according to the source and type of waste, for the labelling, checking, sampling and testing of
waste to be handled.
1.2.5 Dust emissions
1.2.5.1 D i f f u s e d u s t e m i s s i o n s
14. In order to minimise/prevent diffuse dust emissions from dusty operations, BAT is to use one or a combination of
the following techniques:
Technique Applicability
a Use
a
simple
and
linear
site
layout
of
the
installation Applicable
to
new
plants only

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9.4.2013 Official
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Technique Applicability
b Enclose/encapsulate
dusty
operations,
such
as
grinding,
screening
and
mixing Generally
applicable
c Cover
conveyors
and
elevators,
which
are
constructed
as
closed
systems,
if
diffuse
dust
emissions are likely to be released from dusty material
d Reduce
air
leakages
and
spillage
points
e Use
automatic
devices
and
control
systems
f Ensure
trouble-free
operations
g
Ensure proper and complete maintenance of the installation using mobile and stationary
vacuum cleaning.
— During maintenance operations or in cases of trouble with conveying systems,
spillage of materials can take place. To prevent the formation of diffuse dust
during removal operations, vacuum systems should be used. New buildings can
easily be equipped with stationary vacuum cleaning piping, while existing buildings
are normally better fitted with mobile systems and flexible connections
— In specific cases, a circulation process could be favoured for pneumatic conveying
systems
h Ventilate
and
collect
dust
in
fabric
filters:
— As far as possible, all material handling should be conducted in closed systems
maintained under negative pressure. The suction air for this purpose is then
dedusted by a fabric filter before being emitted into the air
i Use
closed
storage
with
an
automatic
handling
system:
— Clinker silos and closed fully automated raw material storage areas are considered the
most efficient solution to the problem of diffuse dust generated by high volume
stocks. These types of storage are equipped with one or more fabric filters to
prevent diffuse dust formation in loading and unloading operations
— Use storage silos with adequate capacities, level indicators with cut out switches and
with filters to deal with dust-bearing air displaced during filling operations
j Use
flexible
filling
pipes
for
dispatch
and
loading
processes,
equipped
with
a
dust
extraction system for loading cement, which are positioned towards the loading floor
of the lorry
15. In order to minimise/prevent diffuse dust emissions from bulk storage areas, BAT is to use one or a combination
of the following techniques:
Technique
a
Cover bulk storage areas or stockpiles or enclose them with screening, walling or an enclosure consisting of
vertical greenery (artificial or natural wind barriers for open pile wind protection)
b Use
open
pile
wind
protection:
— Outdoor storage piles of dusty materials should be avoided, but when they do exist it is possible to reduce
diffuse dust by using properly designed wind barriers
c
Use water spray and chemical dust suppressors:
— When the point source of diffuse dust is well localised, a water spray injection system can be installed. The
humidification of dust particles aids agglomeration and so helps dust settle. A wide variety of agents is also
available to improve the overall efficiency of the water spray

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L 100/16
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Official Journal of the European Union
9.4.2013
Technique
d Ensure
paving,
road
wetting
and
housekeeping:
— Areas used by lorries should be paved when possible and the surface should be kept as clean as possible.
Wetting the roads can reduce diffuse dust emissions, especially during dry weather. They also can be cleaned
with road sweepers. Good housekeeping practices should be used in order to keep diffuse dust emissions to a
minimum
e Ensure
humidification
of
stockpiles:
— Diffuse dust emissions at stockpiles can be reduced by using sufficient humidification of the charging and
discharging points, and by using conveyor belts with adjustable heights
f
Match the discharge height to the varying height of the heap, automatically if possible or by reduction of the
unloading velocity, when diffuse dust emissions at the charging or discharging points of storage sites cannot be
avoided
1.2.5.2 C h a n n e l l e d d u s t e m i s s i o n s f r o m d u s t y o p e r a t i o n s
This section concerns dust emissions arising from dusty operations other than those from kiln firing, cooling and the
main milling processes. This covers processes such as the crushing of raw materials; raw material conveyors and elevators;
the storage of raw materials, clinker and cement; the storage of fuels and the dispatch of cement.
16. In order to reduce channelled dust emissions, BAT is to apply a maintenance management system which especially
addresses the performance of filters applied to dusty operations, other than those from kiln firing, cooling and main
milling processes. Taking this management system into account, BAT is to use dry flue-gas cleaning with a filter.
Description
For dusty operations, dry flue-gas cleaning with a filter usually consists of a fabric filter. A description of fabric filters is
provided in Section 1.5.1.
BAT-associated emission levels
The BAT-AEL for channelled dust emissions from dusty operations (other than those from kiln firing, cooling and the
main milling processes) is < 10 mg/Nm 3 , as the average over the sampling period (spot measurement, for at least half an
hour).
It should be noted that for small sources (< 10 000 Nm 3 /h) a priority approach, based on the maintenance management
system, regarding the frequency for checking the performance of the filter has to be taken into account (see also BAT 5).
1.2.5.3 D u s t e m i s s i o n s f r o m k i l n f i r i n g p r o c e s s e s
17. In order to reduce dust emissions from flue-gases of kiln firing processes, BAT is to use dry flue-gas cleaning with
a filter.
Technique ( 1 ) Applicability
a Electrostatic
precipitators
(ESPs) Applicable
to
all
kiln
systems
b Fabric
filters
c Hybrid
filters
( 1 ) A description of the techniques is given in Section 1.5.1.
BAT-associated emission levels
The BAT-AEL for dust emissions from flue-gases of kiln firing processes is <10 – 20 mg/Nm 3 , as the daily average value.
When applying fabric filters or new or upgraded ESPs, the lower level is achieved.
1.2.5.4 D u s t e m i s s i o n s f r o m c o o l i n g a n d m i l l i n g p r o c e s s e s
18. In order to reduce dust emissions from the flue-gases of cooling and milling processes, BAT is to use dry flue-gas
cleaning with a filter.

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EN
9.4.2013 Official
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the
European
Union L
100/17
Technique ( 1 ) Applicability
a Electrostatic
precipitators
(ESPs) Generally
applicable
to
clinker
coolers
and
cement
mills.
b Fabric
filters Generally
applicable
to
clinker
coolers
and
mills
c Hybrid
filters Applicable
to
clinker
coolers
and
cement
mills.
( 1 ) A description of the techniques is given in Section 1.5.1
BAT-associated emission levels
The BAT-AEL for dust emissions from the flue-gases of cooling and milling processes is <10 – 20 mg/Nm 3 , as the daily
average value or average over the sampling period (spot measurements for at least half an hour). When applying fabric
filters or new or upgraded ESPs, the lower level is achieved.
1.2.6 Gaseous compounds
1.2.6.1 N O x e m i s s i o n s
19. In
order
to
reduce
the
emissions
of
NO x from the flue-gases of kiln firing and/or preheating/precalcining processes,
BAT is to use one or a combination of the following techniques:
Technique ( 1 ) Applicability
a Primary
techniques
I. Flame cooling Applicable
to
all
types
of
kilns
used
for
cement
manu
facturing. The degree of applicability can be limited by
product quality requirements and potential impacts on
process stability
II. Low NO x burners Applicable
to
all
rotary
kilns,
in
the
main
kiln
as
well
as in the precalciner
III. Mid-kiln firing Generally
applicable
to
long
rotary
kilns
IV. Addition of mineralisers to improve the burn Generally applicable to rotary kilns subject to final
ability of the raw meal (mineralised clinker)
product quality requirements
V. Process optimisation Generally
applicable
to
all
kilns
b Staged
combustion
(conventional
or
waste
fuels),
also
In general, can only be applied in kilns equipped with a
in combination with a precalciner and the use of precalciner. Substantial plant modifications are
optimised fuel mix
necessary in cyclone preheater systems without a
precalciner.
In kilns without precalciner, lump fuels firing might
have a positive effect on NO x reduction depending
on the ability to produce a controlled reduction
atmosphere and to control the related CO emissions
c Selective
non-catalytic
reduction
(SNCR) In
principle,
applicable
to
rotary
cement
kilns.
The
injection zones vary with the type of kiln process. In
long wet and long dry process kilns it may be difficult
to obtain the right temperature and retention time
needed. See also BAT 20
d Selective
catalytic
reduction
(SCR) Applicability
is
subject
to
appropriate
catalyst
and
process development in the cement industry
( 1 ) A description of the techniques is provided in Section 1.5.2.

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L 100/18
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Official Journal of the European Union
9.4.2013
BAT-associated emission levels
See Table 2.
Table 2
BAT-associated emission levels for NO x from the flue-gases of kiln firing and/or preheating/precalcining
processes in the cement industry
Kiln type Unit
BAT-AEL
(daily average value)
Preheater kilns mg/Nm 3
< 200 – 450 ( 1 ) ( 2 )
Lepol and long rotary kilns mg/Nm 3
400 – 800 ( 3 )
( 1 ) The upper level of the BAT-AEL range is 500 mg/Nm 3 , if the initial NO x level after primary techniques is > 1 000 mg/Nm 3 .
( 2 ) Existing kiln system design, fuel mix properties including waste and raw material burnability (e.g. special cement or white cement
clinker) can influence the ability to be within the range. Levels below 350 mg/Nm 3 are achieved at kilns with favourable conditions
when using SNCR. In 2008, the lower value of 200 mg/Nm 3 has been reported as a monthly average for three plants (easy burning
mix used) using SNCR.
( 3 ) Depending on initial levels and NH 3 slip.
20.
When SNCR is used, BAT is to achieve efficient NO x reduction, while keeping the ammonia slip as low as possible,
by using the following technique:
Technique
a To
apply
an
appropriate
and
sufficient
NO x reduction efficiency along with a stable operating process
b
To apply a good stoichiometric distribution of ammonia in order to achieve the highest efficiency of NO x
reduction and to reduce the NH 3 slip
c
To keep the emissions of NH 3 slip (due to unreacted ammonia) from the flue-gases as low as possible taking
into account the correlation between the NO x abatement efficiency and the NH 3 slip
Applicability
SNCR is generally applicable to rotary cement kilns. The injection zones vary with the type of kiln process. In long wet
and long dry process kilns it may be difficult to obtain the right temperature and retention time needed. See also BAT 19.
BAT-associated emission levels
See Table 3.
Table 3
BAT-associated emission levels for NH 3 slip in the flue-gases when SNCR is applied
Parameter Unit
BAT-AEL
(daily average value)
NH 3 slip mg/Nm 3
< 30 – 50 ( 1 )
( 1 ) The ammonia slip depends on the initial NO x level and on the NO x abatement efficiency. For Lepol and long rotary kilns, the level may
be even higher.
1.2.6.2 S O x e m i s s i o n s
21. In
order
to
reduce/minimise
the
emissions
of
SO x from the flue-gases of kiln firing and/or preheating/precalcining
processes, BAT is to use one of the following techniques:

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EN
9.4.2013 Official
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European
Union L
100/19
Technique ( 1 ) Applicability
a Absorbent
addition Absorbent
addition
is,
in
principle,
applicable
to
all
kiln
systems,
although it is mostly used in suspension preheaters. Lime
addition to the kiln feed reduces the quality of the granules/
nodules and causes flow problems in Lepol kilns. For preheater
kilns it has been found that direct injection of slaked lime into
the flue-gas is less efficient than adding slaked lime to the kiln
feed
b Wet
scrubber Applicable
to
all
cement
kiln
types
with
appropriate
(sufficient)
SO 2 levels for manufacturing the gypsum
( 1 ) A description of the techniques is provided in Section 1.5.3
Description
Depending on the raw materials and the fuel quality, levels of SO x emissions can be kept low not requiring the use of an
abatement technique.
If necessary, primary techniques and/or abatement techniques such as absorbent addition or wet scrubber can be used to
reduce SO x emissions.
Wet scrubbers have already been operated in plants with initial unabated SO x levels higher than 800 – 1 000 mg/Nm 3 .
BAT-associated emission levels
See Table 4.
Table 4
BAT-associated emission levels for SO x from the flue-gases of kiln firing and/or preheating/precalcining
processes in the cement industry
Parameter Unit
BAT-AEL ( 1 ) ( 2 )
(daily average value)
SO x expressed as SO 2
mg/Nm 3
< 50 – 400
( 1 ) The range takes into account the sulphur content in the raw materials.
( 2 ) For white cement and special cement clinker production, the ability of clinker to retain fuel sulphur might be significantly lower leading
to higher SO X emissions.
22. In
order
to
reduce
SO 2 emissions from the kiln, BAT is to optimise the raw milling processes.
Description
The technique consists of optimising the raw milling process so that the raw mill can be operated to act as SO 2
abatement for the kiln. This can be achieved by adjusting factors such as:
— raw material moisture
— mill temperature
— retention time in the mill
— fineness of the ground material.
Applicability
Applicable if the dry milling process is used in compound mode.

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Official Journal of the European Union
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1.2.6.3 C O e m i s s i o n s a n d C O t r i p s
1.2.6.3.1 Reduction of CO trips
23. In order to minimise the frequency of CO trips and keep their total duration to below 30 minutes annually, when
using electrostatic precipitators (ESPs) or hybrid filters, BAT is to use the following techniques in combination:
Technique
a Manage
CO
trips
in
order
to
reduce
the
ESP
downtime
b
Continuous automatic CO measurements by means of monitoring equipment with a short response time and
situated close to the CO source
Description
For safety reasons, due to the risk of explosions, ESPs will have to shut down during elevated CO levels in the flue-gases.
The following techniques prevent CO trips and, therefore, reduce ESP shutdown times:
— control of the combustion process
— control of the organic load of raw materials
— control of the quality of the fuels and fuel feeding system.
Disruptions predominantly happen during the start-up operation phase. For safe operation, the gas analysers for ESP
protection have to be on-line during all operational phases and the ESP downtime can be reduced by using a backup
monitoring system maintained in operation.
The continuous CO monitoring system needs to be optimised for reaction time and should be located close to the CO
source, e.g. at a preheater tower outlet, or at a kiln inlet in the case of a wet kiln application.
When hybrid filters are used, the grounding of the bag support cage with the cell plate is recommended.
1.2.6.4 T o t a l o r g a n i c c a r b o n e m i s s i o n s ( T O C )
24.
In order to keep the emissions of TOC from the flue-gases of the kiln firing processes low, BAT is to avoid feeding
raw materials with a high content of volatile organic compounds (VOC) into the kiln system via the raw material feeding
route.
1.2.6.5 H y d r o g e n c h l o r i d e ( H C l ) a n d h y d r o g e n f l u o r i d e ( H F ) e m i s s i o n s
25. In order prevent/reduce the emissions of HCl from flue-gases of the kiln firing processes, BAT is to use one or a
combination of the following primary techniques:
Technique
a Using
raw
materials
and
fuels
with
a
low
chlorine
content
b
Limiting the amount of chlorine content for any waste that is to be used as raw material and/or fuel in a cement
kiln
BAT-associated emission levels
The BAT-AEL for the emissions of HCl is <10 mg/Nm 3 , as the daily average value or average over the sampling period
(spot measurements, for at least half an hour).
26. In order to prevent/reduce the emissions of HF from the flue-gases of the kiln firing processes, BAT is to use one
or a combination of the following primary techniques:

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Technique
a Using
raw
materials
and
fuels
with
a
low
fluorine
content
b
Limiting the amount of fluorine content for any waste that is to be used as raw material and/or fuel in a cement
kiln
BAT-associated emission levels
The BAT-AEL for the emissions of HF is <1 mg/Nm 3 , as the daily average value or average over the sampling period (spot
measurements, for at least half an hour).
1.2.7 PCDD/F emissions
27. In order to prevent emissions of PCDD/F or to keep the emissions of PCDD/F from the flue-gases of the kiln firing
processes low, BAT is to use one or a combination of the following techniques:
Technique Applicability
a Carefully
selecting
and
controlling
of
kiln
inputs
(raw
Generally applicable
materials), i.e. chlorine, copper and volatile organic
compounds
b Carefully
selecting
and
controlling
kiln
inputs
(fuels),
Generally applicable
i.e. chlorine and copper
c Limiting/avoiding
the
use
of
wastes
which
contain
Generally applicable
chlorinated organic materials
d Avoid
feeding
fuels
with
a
high
content
of
halogens
Generally applicable
(e.g. chlorine) in secondary firing
e Quick
cooling
of
kiln
flue-gases
to
lower
than
200
°C
Applicable to long wet kilns and long dry kilns without
and minimising residence time of flue-gases and preheating. In modern preheater and precalciner kilns,
oxygen content in zones where the temperatures this feature is already inherent
range between 300 and 450 °C
f Stop
co-incinerating
waste
for
operations
such
as
Generally applicable
start-ups and/or shutdowns
BAT-associated emission levels
The BAT-AEL for the emissions of PCDD/F from the flue-gases of the kiln firing processes is <0,05 – 0,1 ng PCDD/
F I-TEQ/Nm 3 , as the average over the sampling period (6 – 8 hours).
1.2.8 Metal emissions
28. In order to minimise the emissions of metals from the flue-gases of the kiln firing processes, BAT is to use one or
a combination of the following techniques:
Technique
a
Selecting materials with a low content of relevant metals and limiting the content of relevant metals in materials,
especially mercury
b
Using a quality assurance system to guarantee the characteristics of the waste materials used
c Using
effective
dust
removal
techniques
as
set
out
in
BAT
17
BAT-associated emission levels
See Table 5.

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Table 5
BAT-associated emission levels for metals from the flue-gases of kiln firing processes
BAT-AEL
Metals Unit
(average over the sampling period (spot
measurements, for at least half an hour))
Hg mg/Nm 3
< 0,05 ( 2 )
Σ (Cd, Tl) mg/Nm 3
< 0,05 ( 1 )
Σ (As, Sb, Pb, Cr, Co, Cu, Mn, Ni, V) mg/Nm 3
< 0,5 ( 1 )
( 1 ) Low levels have been reported based on the quality of the raw materials and the fuels.
( 2 ) Low levels have been reported based on the quality of the raw materials and the fuels. Values higher than 0,03 mg/Nm 3 have to be
further investigated. Values close to 0,05 mg/Nm 3 require consideration of additional techniques (e.g. lowering of the flue-gas
temperature, activated carbon).
1.2.9 Process losses/waste
29. In
order
to
reduce
solid
waste
from
the
cement
manufacturing
process
along
with
raw
material
savings,
BAT
is
to:
Technique Applicability
a Reuse
collected
dusts
in
the
process,
wherever
prac Generally applicable but subject to dust chemical
ticable
composition
b Utilise
these
dusts
in
other
commercial
products,
The utilisation of the dusts in other commercial
when possible
products may not be within the control of the operator
Description
Collected dust can be recycled back into the production processes whenever practicable. This recycling may take place
directly into the kiln or kiln feed (the alkali metal content being the limiting factor) or by blending with finished cement
products. A quality assurance procedure might be required when the collected dusts are recycled back into the production
processes. Alternative uses may be found for material that cannot be recycled (e.g. additive for flue-gas desulphurisation in
combustion plants).
1.3 BAT conclusions for the lime industry
Unless otherwise stated, the BAT conclusions presented in this section can be applied to all installations in the lime
industry.
1.3.1 General primary techniques
30.
In order to reduce all kiln emissions and use energy efficiently, BAT is to achieve a smooth and stable kiln process,
operating close to the process parameter set points by using the following techniques:
Technique
a Process
control
optimisation,
including
computer-based
automatic
control
b Using
modern,
gravimetric
solid
fuel
feed
systems
and/or
gas
flow
meters
Applicability
Process control optimisation is applicable to all lime plants to varying degrees. Complete process automation is generally
not achievable due to the uncontrollable variables, i.e. quality of the limestone.
31. In order to prevent and/or reduce emissions, BAT is to carry out a careful selection and control of the raw
materials entering the kiln.

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Description
Raw materials entering the kiln have a significant effect on air emissions due to their impurities content; hence, a careful
selection of raw materials may reduce these emissions at source. For example, the variations of sulphur and chlorine
contents in the limestone/dolomite have an effect on the range of the SO 2 and HCl emissions in the flue-gas, while the
presence of organic matter has an influence on TOC and CO emissions.
Applicability
The applicability depends on the (local) availability of raw materials with low impurities content. The type of final product
and the type of kiln used may represent an additional constraint.
1.3.2 Monitoring
32. BAT is to carry out monitoring and measurements of process parameters and emissions on a regular basis and to
monitor emissions in accordance with the relevant EN standards or, if EN standards are not available, ISO, national or
other international standards that ensure the provision of data of an equivalent scientific quality, including the following:
Technique Applicability
a Continuous
measurements
of
process
parameters
Applicable to kiln processes
demonstrating the process stability, such as
temperature, O 2 content, pressure, flow rate and
CO emissions
b Monitoring
and
stabilising
of
critical
process
parameters, e.g. fuel feed, regular dosage and
excess oxygen
c Continuous
or
periodic
measurements
of
dust,
NO x , Applicable to kiln processes
SO x , CO emissions and NH 3 emissions when SNCR
is applied
d Continuous
or
periodic
measurements
of
HCl
and
Applicable to kiln processes
HF emissions in case wastes are co-incinerated
e Continuous
or
periodic
measurements
of
TOC
Applicable to kiln processes
emissions or continuous measurements in case
wastes are co-incinerated
f
Periodic measurements of PCDD/F and metal Applicable to kiln processes
emissions
g Continuous
or
periodic
measurements
of
dust
Applicable to non-kiln processes
emissions
For small sources (<10 000 Nm 3 /h) the frequency of
the measurements should be based on a maintenance
management system
Description
The selection between continuous or periodic measurements mentioned in BAT 32(c) to 32(f) is based on the emission
source and the type of pollutant expected.
For periodic measurements of dust, NO x , SO x and CO emissions, a frequency of once a month and up to once a year at
the time of normal operating conditions is given as an indication.
For periodic measurements of PCDD/F, TOC, HCl, HF, metal emissions, a frequency appropriate to the raw materials and
fuels that are used in the process should be applied.
1.3.3 Energy consumption
33. In order to reduce/minimise thermal energy consumption, BAT is to use a combination of the following tech
niques:

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Technique Description Applicability
a Applying
improved
and
optimised
Maintaining kiln control
Technique (a) II is applicable only to
kiln systems and a smooth and parameters close to their
long rotary kilns (LRK)
stable kiln process, operating optimum values has the effect of
close to the process parameter set reducing all consumption
points, through:
parameters due to, among other
things, reduced numbers of
I. process control optimisation
shutdowns and upset conditions.
II. heat recovery from flue-gases The use of optimised grain size of
(e.g. use of surplus heat from stone is subject to raw material
rotary kilns to dry limestone availability
for other processes such as
limestone milling)
III. modern, gravimetric solid fuel
feed systems
IV. maintenance of the equipment
(e.g. air tightness, erosion of
refractory)
V. the use of optimised grain size
of stone
b Using
fuels
with
characteristics
The characteristics of fuels, e.g. The applicability depends on the
which have a positive influence high calorific value and low technical possibility to feed the
on thermal energy consumption
moisture content can have a selected fuel into the kiln and on
positive effect on the thermal the availability of suitable fuels (e.g.
energy consumption
high calorific value and low
humidity) which may be impacted
by the energy policy of the
Member State
c Limiting
excess
air A
decrease
of
excess
air
used
for
Applicable to LRK and PRK within
combustion has a direct effect on the limits of a potential overheating
fuel consumption since high of some areas in the kiln with
percentages of air require more consequent deterioration of the
thermal energy to heat up the refractory lifetime
excess volume.
Only in LRK and PRK the limi
tation of excess air has an impact
on thermal energy consumption.
The technique has a potential of
increasing TOC and CO emission
BAT-associated consumption levels
See Table 6.
Table 6
BAT-associated levels for thermal energy consumption in the lime and dolime industry
Kiln type
Thermal energy consumption ( 1 )
GJ/tonne of product
Long rotary kilns (LRK) 6,0
–
9,2
Rotary kilns with preheater (PRK) 5,1
–
7,8
Parallel flow regenerative kilns (PFRK) 3,2
–
4,2
Annular shaft kilns (ASK) 3,3
–
4,9

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Kiln type
Thermal energy consumption ( 1 )
GJ/tonne of product
Mixed feed shaft kilns (MFSK) 3,4
–
4,7
Other kilns (OK) 3,5
–
7,0
( 1 ) Energy consumption depends on the type of product, the product quality, the process conditions and the raw materials
34. In order to minimise electrical energy consumption, BAT is to use one or a combination of the following
techniques:
Technique
a Using
power
management
systems
b Using
optimised
grain
size
of
limestone
c Using
grinding
equipment
and
other
electricity
based
equipment
with
high
energy
efficiency
Description – Technique (b)
Vertical kilns can usually burn only coarse limestone pebbles. However, rotary kilns with higher energy consumption can
also valorise small fractions and new vertical kilns can burn small granules from 10 mm. The larger granules of kiln feed
stone are used more in vertical kilns than in rotary kilns.
1.3.4 Consumption of limestone
35. In order to minimise limestone consumption, BAT is to use one or a combination of the following techniques:
Technique Applicability
a Specific
quarrying,
crushing
and
well
directed
use
of
Generally applicable in the lime industry; however,
limestone (quality, grain size)
stone processing is dependent on the limestone quality
b
Selecting kilns applying optimised techniques which Applicable to new plants and major upgrades of kiln.
allow for operating with a wider range of limestone
grain sizes to make optimum use of quarried lime Vertical kilns can in principle only burn coarse
stone
limestone pebbles. Fine lime PFRK and/or rotary kilns
can operate with smaller limestone grain sizes
1.3.5 Selection of fuels
36. In order to prevent/reduce emissions, BAT is to carry out a careful selection and control of fuels entering the kiln.
Description
Fuels entering the kiln may have a significant effect on air emissions due to their impurities content. The content of
sulphur (for long rotary kilns in particular), nitrogen and chlorine have an effect on the range of the SO x , NO x and HCl
emissions in the flue-gas. Depending on the chemical composition of the fuel and the type of kiln used, the choice of
appropriate fuels or a fuel mix can lead to emissions reductions.
Applicability
Except for mixed feed shaft kilns, all types of kilns can operate with all types of fuels and fuel mixtures subject to fuels
availability which may be impacted by the energy policy of the Member State. The selection of fuel also depends on the
desired quality of the final product, the technical possibility to feed the fuel into the selected kiln, and economic
considerations.
1.3.5.1 U s e o f w a s t e f u e l s
1.3.5.1.1 Waste quality control
37. In order to guarantee the characteristics of waste to be used as fuel in a lime kiln, BAT is to apply the following
techniques:

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Technique
a
Apply a quality assurance system to guarantee and control the characteristics of wastes and to analyse any waste
that is to be used as fuel in the kiln for:
I. constant quality
II. physical criteria, e.g. emissions formation, coarseness, reactivity, burnability, calorific value
III. chemical criteria, e.g. total chlorine content, sulphur, alkali, and phosphate content and relevant metals
content (e.g. total chromium, lead, cadmium, mercury, thallium)
b
Control the amount of relevant components for any waste that is to be used as fuel, such as total halogen
content, metals (e.g. total chromium, lead, cadmium, mercury, thallium) and sulphur
1.3.5.1.2 Waste feeding into the kiln
38. In order to prevent/reduce emissions occurring from the use of waste fuels into the kiln, BAT is to use the
following techniques:
Technique
a
To use appropriate burners for feeding suitable wastes depending on kiln design and kiln operation
b To
operate
in
such
a
way
that
the
gas
resulting
from
the
co-incineration
of
waste
is
raised
in
a
controlled
and
homogeneous fashion and even under the most unfavourable conditions, to a temperature of 850 °C for 2
seconds
c
To raise the temperature to 1 100 °C if hazardous wastes with a content of more than 1 % of halogenated
organic substances, expressed as chlorine, are co-incinerated
d To
feed
wastes
continuously
and
constantly
e To
stop
feeding
waste
for
operations
such
as
start-ups
and/or
shutdowns
when
appropriate
temperatures
and
residence times cannot be reached, as mentioned in (b) and (c) above
1.3.5.1.3 Safety management for the use of hazardous waste materials
39. In order to prevent accidental emissions, BAT is to use safety management for the storage, handling and feeding
into the kiln of hazardous waste materials.
Description
The use of a safety management for the storage, handling and feeding of hazardous waste materials consists of a risk-
based approach according to the source and type of waste, for the labelling, checking, sampling and testing of waste to be
handled.
1.3.6 Dust emissions
1.3.6.1 D i f f u s e d u s t e m i s s i o n s
40. In order to minimise/prevent diffuse dust emissions from dusty operations, BAT is to use one or a combination of
the following techniques:
Technique
a Enclosure/encapsulation
of
dusty
operations,
such
as
grinding,
screening
and
mixing
b
Use of covered conveyors and elevators, which are constructed as closed systems, if dust emissions are likely to
be released from dusty material
c
Use of storage silos with adequate capacity, level indicators with cut out switches and with filters to deal with
dust-bearing air displaced during filling operations
d Use
of
a
circulation
process
which
is
favoured
for
pneumatic
conveying
systems

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Technique
e
Material handling in closed systems maintained under negative pressure and dedusting of the suction air by a
fabric filter before being emitted into the air
f Reduction
of
air
leakage
and
spillage
points,
completion
of
installation
g Proper
and
complete
maintenance
of
the
installation
h Use
of
automatic
devices
and
control
systems
i Use
of
continuous
trouble-free
operations
j
Use of flexible filling pipes equipped with a dust extraction system for loading lime which are positioned at the
loading floor of the lorry
Applicability
In raw material preparation operations, like crushing and sieving, dust separation is not normally needed, because of the
moisture content of the raw material.
41. In order to minimise/prevent diffuse dust emissions from bulk storage areas, BAT is to use one or a combination
of the following techniques:
Technique
a Enclose
storage
locations
using
screening,
walling
or
vertical
greenery
(artificial
or
natural
wind
barriers
for
open
pile wind protection)
b Use
product
silos
and
closed,
fully-automated
raw
material
storages.
These
types
of
storage
are
equipped
with
one or more fabric filters to prevent diffuse dust formation in loading and unloading operations
c
Reduce diffuse dust emissions at stockpiles by using sufficient humidification of stockpile charging and
discharging points and the use of conveyor belts with adjustable height. When using humidification or
spraying measures/techniques, the ground can be sealed and the surplus water can be gathered, and if
necessary this can be treated and used in closed cycles
d
Reduce diffuse dust emissions at charging or discharging points of storage sites if they cannot be avoided, by
matching the discharge height to the varying height of the heap, if possible automatically, or by reduction of the
unloading velocity
e
Keep the locations wet, especially dry areas, using spraying devices and clean them by cleaning lorries
f Use
vacuum
systems
during
removal
operations.
New
buildings
can
easily
be
equipped
with
stationary
vacuum
cleaning systems, while existing buildings are normally better fitted with mobile systems and flexible connections
g
Reduce diffuse dust emissions arising in areas used by lorries, by paving these areas when possible and keeping
the surface as clean as possible. Wetting the roads can reduce diffuse dust emissions, especially during dry
weather. Good housekeeping practices can be used in order to keep diffuse dust emissions to a minimum
1.3.6.2 C h a n n e l l e d d u s t e m i s s i o n s f r o m d u s t y o p e r a t i o n s o t h e r t h a n t h o s e f r o m k i l n
f i r i n g p r o c e s s e s
42. In order to reduce channelled dust emissions from dusty operations other than those from kiln firing processes,
BAT is to use one of the following techniques and to use a maintenance management system which specifically addresses
the performance of filters:

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Technique ( 1 ) ( 2 ) Applicability
a Fabric
filter Generally
applicable
to
milling
and
grinding
plants
and
subsidiary processes in the lime industry; material
transport; and storage and loading facilities. The appli
cability of fabric filters in hydrating lime plants may be
limited by the high moisture and low temperature of
the flue-gases
b Wet
scrubbers Mainly
applicable
to
hydrating
lime
plants
( 1 ) A description of the techniques is provided in Section 1.6.1.
( 2 ) If necessary, centrifugal separators/cyclones can be used as pretreatment of the flue-gases.
BAT-associated emission levels
See Table 7.
Table 7
BAT-associated emission levels for channelled dust emissions from dusty operations other than those from kiln
firing processes
BAT-AEL
Technique Unit
(daily average or average over the sampling
period (spot measurements for at least half an
hour))
Fabric filter mg/Nm 3
< 10
Wet scrubber mg/Nm 3
< 10 – 20
It should be noted that for small sources (< 10 000 Nm 3 /h) a priority approach regarding the frequency for checking the
performance of the filter has to be taken into account (see BAT 32).
1.3.6.3 D u s t e m i s s i o n s f r o m k i l n f i r i n g p r o c e s s e s
43. In order to reduce dust emissions from the flue-gases of kiln firing processes, BAT is to use flue-gas cleaning with
a filter. One or a combination of the following techniques can be used:
Technique ( 1 ) Applicability
a ESP Applicable
to
all
kiln
systems
b Fabric
filter Applicable
to
all
kiln
systems
c Wet
dust
separator Applicable
to
all
kiln
systems
d Centrifugal
separator/cyclone Centrifugal
separators
are
only
suitable
as
pre-
separators and can be used to pre-clean the flue-gases
from all kiln systems
( 1 ) A description of the techniques is provided in Section 1.6.1.
BAT-associated emission levels
See Table 8.
Table 8
BAT-associated emission levels for dust emissions from the flue-gases of kiln firing processes
BAT-AEL
Technique Unit
(daily average value or average over the
sampling period (spot measurements for at
least half an hour))
Fabric filter mg/Nm 3
< 10
ESP or other filters mg/Nm 3
< 20 (*)
(*) In exceptional cases where the resistivity of dust is high, the BAT-AEL could be higher, up to 30 mg/Nm 3 , as the daily average value.

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1.3.7 Gaseous compounds
1.3.7.1 P r i m a r y t e c h n i q u e s f o r r e d u c i n g e m i s s i o n s o f g a s e o u s c o m p o u n d s
44. In order to reduce the emissions of gaseous compounds (i.e. NO x , SO x , HCl, CO, TOC/VOC, volatile metals) from
the flue-gases of kiln firing processes, BAT is to use one or a combination of the following techniques:
Technique Applicability
a Careful
selection
and
control
of
substances
entering
Generally applicable
the kiln
b Reducing
the
pollutant
precursors
in
fuels
and,
if
Generally applicable in the lime industry subject to
possible, in raw materials, i.e.
local availability of raw materials and fuels, the type
of kiln used, the desired product qualities and the
I. selecting fuels, where available, with low contents technical possibility of feeding the fuels into the
of sulphur (for long rotary kilns in particular), selected kiln
nitrogen and chlorine
II. selecting raw materials, if possible, with low
contents of organic matter
III. selecting suitable waste fuels for the process and
the burner
c Using
process
optimisation
techniques
to
ensure
an
Applicable to all lime plants.
efficient absorption of sulphur dioxide (e.g. efficient
contact between the kiln gases and the quicklime)
In general, complete process automation is not
achievable due to uncontrollable variables, i.e. quality
of the limestone
1.3.7.2 N O x e m i s s i o n s
45. In
order
to
reduce
the
emissions
of
NO X from the flue-gases of kiln firing processes, BAT is to use one or a
combination of the following techniques:
Technique Applicability
a Primary
techniques
I. Appropriate fuel selection along with limitation Generally applicable in the lime industry subject to fuel
of nitrogen content in the fuel
availability which may be impacted by the energy
policy of the Member State and to the technical possi
bility to feed a certain type of fuel into the selected kiln
II. Process optimisation including flame shaping and Optimisation of process and process control can be
temperature profile
applied in lime manufacturing but is subject to the
final product quality
III. Burner design (low NO X burner) ( 1 ) Low
NO X burners are applicable to rotary kilns and to
annular shaft kilns presenting conditions of high
primary air. PFRKs and other shaft kilns have
flameless combustion, thus rendering low NO X
burners not applicable to this kiln type
IV. Air staging ( 1 ) Not
applicable
to
shaft
kilns.
Applicable only to PRK but not when hard burned lime
is produced. The applicability may be limited by
constraints imposed by the type of final product, due
to possible overheating in some areas of the kiln and
consequent deterioration of the refractory lining
b SNCR
( 1 ) Applicable
to
Lepol
rotary
kilns.
See
also
BAT
46
( 1 ) A description of the techniques is provided in Section 1.6.2

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BAT-associated emission levels
See Table 9.
Table 9
BAT-associated emission levels for NO x from flue-gases of kiln firing processes in the lime industry
BAT-AEL
Kiln type Unit
(daily average value or average over the
sampling period (spot measurements for at
least half an hour), stated as NO 2 )
PFRK, ASK, MFSK, OSK mg/Nm 3
100 – 350 ( 1 ) ( 3 )
LRK, PRK mg/Nm 3
< 200 – 500 ( 1 ) ( 2 )
( 1 ) The higher ends of the ranges are related to the production of dolime and hard burned lime. Higher levels than the upper end of the
range may be associated with the production of sintered dolime.
( 2 ) For LRK and PRK with shaft producing hard burned lime, the upper level is up to 800 mg/Nm 3
( 3 ) Where primary techniques as indicated in BAT 45 (a)I are not sufficient to reach this level and where secondary techniques are not
applicable to reduce the NO x emissions to 350 mg/Nm 3 , the upper level is 500 mg/Nm 3 , especially for hard burned lime and for the
use of biomass as fuel.
46.
When SNCR is used, BAT is to achieve efficient NO x reduction, while keeping the ammonia slip as low as possible,
by using the following technique:
Technique
a To
apply
an
appropriate
and
sufficient
reduction
efficiency
along
with
a
stable
operating
process
b To
apply
a
good
stoichiometric
ratio
and
distribution
of
ammonia
in
order
to
achieve
the
highest
efficiency
of
NO x reduction and to reduce the ammonia slip
c To
keep
the
emissions
of
NH 3 slip (due to unreacted ammonia) from the flue-gases as low as possible, taking
into account the correlation between the NO x abatement efficiency and the NH 3 slip.
Applicability
Applicable only to Lepol rotary kilns, where the ideal temperature range of 850 to 1 020 °C is accessible. See also BAT
45, technique (b).
BAT-associated emission levels
The BAT-AEL for the emissions of NH 3 slip from the flue-gases is <30 mg/Nm 3 , as the daily average value or average
over the sampling period (spot measurements for at least half an hour).
1.3.7.3 S O x e m i s s i o n s
47. In
order
to
reduce
the
emissions
of
SO x from the flue-gases of kiln firing processes, BAT is to use one or a
combination of the following techniques:
Technique Applicability
a Process
optimisation
to
ensure
an
efficient
absorption
Process control optimisation is applicable to all lime
of sulphur dioxide (e.g. efficient contact between the plants
kiln gases and the quicklime)
b Selecting
fuels
with
a
low
sulphur
content Generally
applicable,
subject
to
fuel
availability
in
particular for use in long rotary kilns (LRK), due to
high SO x emissions
c Using
absorbent
addition
techniques
(e.g.
absorbent
Absorbent addition techniques are, in principle,
addition, dry flue-gas cleaning with a filter, wet applicable in the lime industry; however, this
scrubber, or activated carbon injection) ( 1 )
technique had not yet been applied in the lime sector
in 2007. Particularly for rotary lime kilns further inves
tigation is required in order to assess its applicability
( 1 ) A description of the techniques is provided in Section 1.6.3

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European
Union L
100/31
BAT-associated emission levels
See Table 10.
Table 10
BAT-associated emission levels for SO x from flue-gases of kiln firing processes in the lime industry
BAT-AEL ( 1 ) ( 2 )
Kiln type Unit
(daily average value or average over the
sampling period (spot measurements for at
least half an hour), SO x expressed as SO 2 )
PFRK, ASK, MFSK, OSK, PRK mg/Nm 3
< 50 – 200
LRK mg/Nm 3
< 50 – 400
( 1 ) The level depends on the initial SO x level in the flue-gas and on the reduction technique used.
( 2 ) For the production of sintered dolime using the ‘double- pass process’, SO x emissions might be higher than the upper end of the range.
1.3.7.4 C O e m i s s i o n s a n d C O t r i p s
1.3.7.4.1 CO emissions
48. In order to reduce the emissions of CO from the flue-gases of kiln firing processes, BAT is to use one or a
combination of the following techniques:
Technique Applicability
a Selecting,
raw
materials
with
a
low
content
of
organic
Generally applicable to the lime industry within the
matter
constraints of the local availability and composition
of raw materials, the type of kiln used and the
quality of the final product
b Using
process
optimisation
techniques
to
achieve
a
Applicable to all lime plants.
stable and complete combustion
In general, complete process automation is not
achievable due to uncontrollable variables, i.e. quality
of the limestone
In this context, see also BAT 30 and 31 in Section 1.3.1 and BAT 32 in Section 1.3.2.
BAT-associated emission levels
See Table 11.
Table 11
BAT-associated emission levels for CO from the flue-gas of kiln firing processes
BAT-AEL ( 1 ) ( 2 )
Kiln type Unit
(daily average value or average over the
sampling period (spot measurements for at
least half an hour))
PFRK, OSK, LRK, PRK mg/Nm 3
< 500
( 1 ) Emissions can be higher depending on raw materials used and/or type of lime produced, e.g. hydraulic lime.
( 2 ) BAT-AEL does not apply to MFSK and ASK.
1.3.7.4.2 Reduction of CO trips
49. In order to minimise the frequency of CO trips when using electrostatic precipitators, BAT is to use the following
techniques:
Technique
a Manage
CO
trips
in
order
to
reduce
the
ESP
downtime
b
Continuous automatic CO measurements by means of monitoring equipment with a short response time and
situated close to the CO source

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Official Journal of the European Union
9.4.2013
Description
For safety reasons, due to the risk of explosions, ESPs will have to shut down during elevated CO levels in the flue-gases.
The following techniques prevent CO trips and, therefore, reduce ESP shutdown times:
— control of the combustion process
— control of the organic load of raw materials
— control of the quality of the fuels and fuel feeding system.
Disruptions predominantly happen during the start-up operation phase. For safe operation, the gas analysers for ESP
protection have to be online during all operational phases and the ESP downtime can be reduced by using a backup
monitoring system maintained in operation.
The continuous CO monitoring system needs to be optimised for reaction time and should be located close to the CO
source, e.g. at a preheater tower outlet, or at a kiln inlet in the case of a wet kiln application.
Applicability
Generally applicable to rotary kilns fitted with electrostatic precipitators (ESPs).
1.3.7.5 T o t a l o r g a n i c c a r b o n e m i s s i o n s ( T O C )
50. In order to reduce the emissions of TOC from the flue-gases of kiln firing processes, BAT is to use one or a
combination of the following techniques:
Technique
a
Applying general primary techniques and monitoring (see also BAT 30 and 31 in Section 1.3.1, and BAT 32 in
Section 1.3.2)
b
Avoid feeding raw materials with a high content of volatile organic compounds into the kiln system (except for
hydraulic lime production)
Applicability
For applicability of general primary techniques and monitoring see BAT 30 and 31 in Section 1.3.1, and BAT 32 in
Section 1.3.2.
Technique (b) is generally applicable to the lime industry, subject to local raw materials availability and/or the type of lime
produced.
BAT-associated emission levels
See Table 12.
Table 12
BAT-associated emission levels for TOC from the flue-gas of kiln firing processes
BAT-AEL ( 1 )
Kiln type Unit
(daily average value or average over the
sampling period (spot measurements for at
least half an hour))
LRK, PRK mg/Nm 3
< 10
ASK, MFSK ( 2 ), PFRK ( 2 ) mg/Nm 3
< 30
( 1 ) Level can be higher depending on the content of organic matter of raw materials used and/or the type of lime produced, in particular
for the production of natural hydraulic lime.
( 2 ) In exceptional cases, the level can be higher.

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Union L
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1.3.7.6 H y d r o g e n c h l o r i d e ( H C l ) a n d h y d r o g e n f l u o r i d e ( H F ) e m i s s i o n s
51. In order to reduce the emissions of HCl and the emissions of HF from the flue-gas of kiln firing processes, when
using waste, BAT is to use the following primary techniques:
Technique
a Using
conventional
fuels
with
a
low
chlorine
and
fluorine
content
b
Limiting the amount of chlorine and fluorine content for any waste that is to be used as fuel in a lime kiln
Applicability
The techniques are generally applicable in the lime industry but subject to local availability of suitable fuel.
BAT-associated emission levels
See Table 13.
Table 13
BAT-associated emission levels for HCl and HF emissions from the flue-gas of kiln firing processes, when using
wastes
BAT-AEL
Emission Unit
(daily average value or the average value
over the sampling period (spot measure
ments, for at least half an hour))
HCl mg/Nm 3
< 10
HF mg/Nm 3
< 1
1.3.8 PCDD/F emissions
52.
In order to prevent or reduce the emissions of PCDD/F from the flue-gas of kiln firing processes, BAT is to use one
or a combination of the following primary techniques:
Technique
a Selecting
fuels
with
a
low
chlorine
content
b
Limiting the copper input through the fuel
c
Minimising the residence time of the flue-gases and the oxygen content in zones where the temperatures range
between 300 and 450 °C
BAT-associated emission levels
The BAT-AELs are < 0,05 – 0,1 ng PCDD/F I-TEQ/Nm 3 , as the average over the sampling period (6 – 8 hours).
1.3.9 Metal emissions
53. In order to minimise the emissions of metals from the flue-gases of kiln firing processes, BAT is to use one or a
combination of the following techniques:
Technique
a Selecting
fuels
with
a
low
content
of
metals
b
Using a quality assurance system to guarantee the characteristics of the waste fuels used
c Limiting
the
content
of
relevant
metals
in
materials,
especially
mercury
d Using
one
or
a
combination
of
dust
removal
techniques
as
set
out
in
BAT
43

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L 100/34
EN
Official Journal of the European Union
9.4.2013
BAT-associated emission levels
See Table 14.
Table 14
BAT associated emission levels for metals from the flue-gases of kiln firing processes, when using wastes
BAT-AEL
Metals Unit
(average over the sampling period (spot
measurements for at least half an hour))
Hg mg/Nm 3
< 0,05
Σ (Cd, Tl) mg/Nm 3
< 0,05
Σ (As, Sb, Pb, Cr, Co, Cu, Mn, Ni, V) mg/Nm 3
< 0,5
NB: Low levels were reported when applying techniques as mentioned in BAT 53 (a) – (d).
Furthermore in this context, see also BAT 37 (Section 1.3.5.1.1) and BAT 38 (Section 1.3.5.1.2).
1.3.10 Process losses/waste
54.
In order to reduce the solid wastes from the lime manufacturing processes and to save raw materials, BAT is to use
the following techniques:
Technique Applicability
a
Reuse the collected dust or other particulate matter Generally applicable whenever practicable
(e.g. sand, gravel) in the process
b Utilise
dust,
off-specification
quicklime
and
off-specifi Generally utilised in different kinds of selected
cation hydrated lime in selected commercial products commercial products, whenever practicable
1.4 BAT conclusions for the magnesium oxide industry
Unless otherwise stated, the BAT conclusions presented in this section can be applied to all installations in the
magnesium oxide industry (dry process route).
1.4.1 Monitoring
55. BAT is to carry out monitoring and measurements of process parameters and emissions on a regular basis and to
monitor emissions in accordance with the relevant EN standards or, if EN standards are not available, ISO, national or
other international standards that ensure the provision of data of an equivalent scientific quality, including the following:
Technique Applicability
a Continuous
measurements
of
process
parameters
Generally applicable to kiln processes
demonstrating the process stability, such as
temperature, O 2 content, pressure, flow rate
b Monitoring
and
stabilising
critical
process
parameters,
i.e. raw material and fuel feed, regular dosage and
excess oxygen
c Continuous
or
periodic
measurements
of
dust,
NO x , Generally applicable to kiln processes
SO x and CO emissions
d Continuous
or
periodic
measurements
of
dust
Applicable to non-kiln processes.
emissions
For small source (< 10 000 Nm 3 /h) the frequency of
the measurements or performance check should be
based on a maintenance management system

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European
Union L
100/35
Description
The selection between continuous or periodic measurements mentioned in BAT 55 (c) is based on the emission source
and the type of pollutant expected.
For periodic measurements for dust, NO x , SO x and CO emissions from kiln processes, a frequency of once a month and
up to once a year and at the time of normal operating conditions is given as an indication.
1.4.2 Energy consumption
56. In order to reduce thermal energy consumption, BAT is to use a combination of the following techniques:
Technique Description Applicability
a Applying
improved
and
optimised
Heat recovery from flue-gases by Process control optimisation is
kiln systems and a smooth and the preliminary heating of the applicable to all kiln types used in
stable kiln process by applying:
magnesite can be used in order to the magnesia industry.
reduce fuel energy use. Heat
I. process control optimisation
recovered from the kiln can be
used for drying fuels, raw
II. heat recovery from flue-gases materials and some packaging
from kiln and coolers
materials
b Using
fuels
with
characteristics
The characteristics of fuels, e.g. Generally applicable subject to avail
which have a positive influence high calorific value and low ability of the fuels, the type of kilns
on thermal energy consumption
moisture content have a positive used, the desired product qualities
effect on the thermal energy and the technical possibilities of
consumption
injecting the fuels into the kiln.
c Limiting
excess
air The
excess
oxygen
level
to
obtain
Generally applicable
the required quality of the products
and for optimal combustion is
usually in practice about 1 – 3 %
BAT-associated consumption levels
The BAT-associated thermal energy consumption is 6 – 12 GJ/t, depending on the process and the products ( 1 ).
57. In order to minimise electrical energy consumption, BAT is to use one or a combination of the following
techniques:
Technique
a Using
power
management
systems
b Using
grinding
equipment
and
other
electricity
based
equipment
with
high
energy
efficiency
1.4.3 Dust emissions
1.4.3.1 D i f f u s e d u s t e m i s s i o n s
58. In order to minimise/prevent diffuse dust emissions from dusty operations, BAT is to use one or a combination of
the following techniques:
Technique
a Simple
and
linear
site
layout
b
Good housekeeping of buildings and roads, along with proper and complete maintenance of the installation
c Watering
of
raw
material
piles
d Enclosure/encapsulation
of
dusty
operations,
such
as
grinding
and
screening
e
Use of covered conveyors and elevators, which are constructed as closed systems, if dust emissions are likely to
be released from dusty material
( 1 ) This range only reflects information provided for the magnesium oxide chapter of the BREF. More specific information about best
performing techniques along with the products produced was not provided.

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L 100/36
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Official Journal of the European Union
9.4.2013
Technique
f
Use of storage silos with adequate capacities and equipping them with filters to deal with dust-bearing air
displaced during filling operations
g A
circulation
process
is
favoured
for
pneumatic
conveying
systems
h Reduction
of
air
leakage
and
spillage
points
i Use
of
automatic
devices
and
control
systems
k Use
of
continuous
trouble-free
operations
1.4.3.2 C h a n n e l l e d d u s t e m i s s i o n s f r o m d u s t y o p e r a t i o n s o t h e r t h a n k i l n f i r i n g
p r o c e s s e s
59. In order to reduce channelled dust emissions from dusty operations other than those from kiln firing processes,
BAT is to use flue-gas cleaning with a filter by applying one or a combination of the following techniques, and to use a
maintenance management system which specifically addresses the performance of techniques:
Technique ( 1 ) Applicability
a Fabric
filters Generally
applicable
to
all
units
in
the
magnesium
oxide manufacturing process, especially for dusty oper
ations, screening, grinding and milling
b Centrifugal
separators/
cyclones Because
of
the
system-dependent
limited
degree
of
separation, cyclones are mainly applicable as
preliminary separators for coarse dust and flue-gases
c Wet
dust
separators Generally
applicable
( 1 ) A description of the techniques is provided in Section 1.7.1
BAT-associated emission levels
The BAT-AEL for channelled dust emissions from dusty operations other than those from kiln firing processes is <
10 mg/Nm 3 , as daily average or average over the sampling period (spot measurements, for at least half an hour).
It should be noted that for small sources (< 10 000 Nm 3 /h) a priority approach, based on a maintenance management
system regarding the frequency for checking the performance of the filter has to be taken into account (see BAT 55).
1.4.3.3 D u s t e m i s s i o n s f r o m t h e k i l n f i r i n g p r o c e s s
60. In order to reduce dust emissions from the flue-gases of kiln firing processes, BAT is to use flue-gas cleaning with
a filter by applying one or a combination of the following techniques:
Technique ( 1 ) Applicability
a Electrostatic
precipitators ESPs are mainly applicable in rotary kilns. They are applicable for flue-gas
(ESPs)
temperatures above the dew point and up to 370 – 400 °C
b Fabric
filters Fabric
filters
for
dust
removal
from
flue-gases
can,
in
principle,
be
applied
for
all
units in the magnesium oxide manufacturing process. They can be used for flue-
gas temperatures above the dew point and up to 280 °C.
For the production of caustic calcined magnesia (CCM) and sintered/dead burned
magnesia (DBM), due to the high temperatures, the corrosive nature and the high
volume of the flue-gases occurring from the kiln firing process, special fabric
filters with high temperature-resistant filter material have to be used. However,
experience from the magnesia industry producing DBM shows that no suitable
equipment is available for flue-gas temperatures of approximately 400 °C for
magnesia production

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Technique ( 1 ) Applicability
c Centrifugal
separators/
Because of the system-dependent limited degree of separation, cyclones are
cyclones
mainly applicable as preliminary separators for coarse dust and flue-gases
d Wet
dust
separators Generally
applicable
( 1 ) A description of the techniques is provided in Section 1.7.1.
BAT-associated emission levels
The BAT-AEL for dust emissions from the flue-gases of kiln firing processes is < 20 – 35 mg/Nm 3 as the daily average
value or average over the sampling period (spot measurements, for at least half an hour).
1.4.4 Gaseous compounds
1.4.4.1 G e n e r a l p r i m a r y t e c h n i q u e s f o r r e d u c i n g e m i s s i o n s o f g a s e o u s c o m p o u n d s
61. In
order
to
reduce
the
emissions
of
gaseous
compounds
(i.e.
NO x , HCl, SO x , CO) from flue-gases of kiln firing
processes, BAT is to use one or a combination of the following primary techniques:
Technique Applicability
a Careful
selection
and
control
of
the
substances
Generally applicable subject to availability of raw
entering the kiln in order to reduce the pollutant materials and fuels, the type of kiln used, the desired
precursors, i.e.:
product qualities and the technical possibility of
injecting the fuels into the selected kiln.
I. selecting fuels with low contents of sulphur, if
available, chlorine and nitrogen
Waste materials can be considered as fuels in the
magnesia industry but had not yet been applied in
II. selecting raw materials with low contents of the magnesia industry in 2007
organic matter
III. selecting suitable waste fuels for the process and
the burner
b Using
process
optimisation
measures/techniques
to
Process control optimisation is applicable to all kiln
ensure a smooth and stable kiln process, operating types used in the magnesia industry. However, a
close to the stoichiometric required air
highly sophisticated process control system may be
necessary
1.4.4.2 N O x e m i s s i o n s
62. In
order
to
reduce
the
emissions
of
NO x from the flue-gases of kiln firing processes, BAT is to use a combination
of the following techniques:
Technique Applicability
a Appropriate
fuel
selection
along
with
a
limited
Generally applicable subject to fuels availability
nitrogen content in the fuel
b
Process optimisation and improved firing technique Generally
applicable
in
the
magnesia
industry
BAT-associated emission levels
The BAT-AEL for the emissions of NO X from the flue-gases of kiln firing processes is < 500 – 1 500 mg/Nm 3 , as the
daily average value or average over the sampling period (spot measurements for at least half an hour) stated as NO 2 . The
higher values are related to the high temperature DBM process.
1.4.4.3 C O e m i s s i o n s a n d C O t r i p s
1.4.4.3.1 CO emissions
63.
In order to reduce the emissions of CO from the flue-gases of kiln firing processes, BAT is to use a combination of
the following techniques:

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L 100/38
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Official Journal of the European Union
9.4.2013
Technique Description
a Selecting
raw
materials
with
a
low
content
of
organic
A part of CO emissions results from the organic matter
matter
of raw materials thus selection of raw materials with
low organic content can reduce CO emissions
b Process
control
optimisation A
complete
and
correct
combustion
is
essential
to
reduce CO emissions. Air supply from cooler and
primary air as well as the draught of the stack fan
can be controlled in order to keep an oxygen level of
between 1 (sinter) and 1,5 % (caustic) during the
combustion. A change of air and fuel charge can
reduce CO emissions. Furthermore, CO emissions can
be decreased by changing the depth of the burner
c Feeding
fuels
controlled,
constantly
and
continuously Controlled
fuel
addition
includes,
e.g.:
— using weight feeders and precision rotary valves for
petcoke feeding and/or
— using flow meters and precision valves for heavy oil
or gas feeding regulation to the kiln burner
Applicability
The techniques for the reduction of CO emissions are generally applicable to the magnesia industry. The selection of raw
materials with a low content of organic matter is subject to raw materials availability.
BAT-associated emission levels
The BAT-AEL for the emissions of CO from the flue-gases of kiln firing processes is < 50 – 1 000 mg/Nm 3 , as the daily
average value or average over the sampling period (spot measurements for at least half an hour).
1.4.4.3.2 Reduction of CO trips
64. In order to minimise the number of CO trips when applying ESPs, BAT is to use the following techniques:
Technique
a Manage
CO
trips
in
order
to
reduce
the
ESP
downtime
b
Continuous automatic CO measurements by means of monitoring equipment with a short response time and
situated close to the CO source
Description
For safety reasons, due to the risk of explosions, ESPs will have to shut down during elevated CO levels in the flue-gases.
The following techniques prevent CO trips and, therefore, reduce ESP shutdown times:
— control of the combustion process
— control of the organic load of raw materials
— control of the quality of the fuels and fuel feeding system.
Disruptions predominantly happen during the start-up operation phase. For safe operation, the gas analysers for ESP
protection have to be online during all operational phases and the ESP downtime can be reduced by using a backup
monitoring system maintained in operation.
The continuous CO monitoring system needs to be optimised for reaction time and should be located close to the CO
source, e.g. at a preheater tower outlet, or at a kiln inlet in the case of a wet kiln application.
Applicability
Generally applicable to kilns fitted with electrostatic precipitators (ESPs).

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9.4.2013 Official
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European
Union L
100/39
1.4.4.4 S O x e m i s s i o n s
65. In
order
to
reduce
the
emissions
of
SO x from the flue-gases of kiln firing processes, BAT is to use a combination
of the following primary and secondary techniques:
Technique Applicability
a Process
optimisation
techniques Generally
applicable
b Selecting
fuels
with
a
low
sulphur
content Generally
applicable
subject
to
availability
of
low
sulphur fuels which may be impacted by the energy
policy of the Member State. The selection of fuel also
depends on the quality of the final product, technical
possibilities and economic considerations
c A
dry
absorbent
addition
technique
(sorbent
addition
Generally applicable
into the flue gas stream such as reactive MgO grades,
hydrated lime, activated carbon, etc.), in combination
with a filter ( 1 )
d Wet
scrubber
( 1 ) The
applicability
may
be
limited
in
arid
areas
by
the
large volume of water necessary and the need for waste
water treatment and the related cross-media effects
( 1 ) A description of the measure/technique is provided in Section 1.7.2
BAT-associated emission levels
See Table 15.
Table 15
BAT-associated emission levels for SO x from flue-gases of kiln firing processes in the magnesia industry
BAT-AEL ( 1 ) ( 2 )
Parameter Unit
(daily average value or average over the
sampling period (spot measurements for at
least half an hour))
SO X expressed as SO 2
mg/Nm 3
< 50 – 400 ( 3 )
( 1 ) The BAT-AELs depend on the content of sulphur in the raw materials and fuels. The lower end of the range is associated with the use
of raw materials with low sulphur content and the use of natural gas; the upper end of the range is associated with the use of raw
materials with higher sulphur content and/or the use of sulphur-containing fuels.
( 2 ) Cross-media effects should be taken into account to assess the best combination of BAT to reduce SO x emissions.
( 3 ) When a wet scrubber is not applicable, BAT-AELs depend on the sulphur content of raw materials and fuels. In this case, the BAT-AEL
is < 1 500 mg/Nm 3 while ensuring a SO X emissions removal efficiency of at least 60 %.
1.4.5 Process losses/waste
66. In
order
to
reduce/minimise
process
losses/waste,
BAT
is
to
reuse
various
types
of
collected
magnesium
carbonate
dusts in the process.
Applicability
Generally applicable, subject to dust chemical composition.
67. In order to reduce/minimise process losses/waste, BAT is to utilise the various types of collected magnesium
carbonate dusts in other marketable products when these are not recyclable.
Applicability
The utilisation of magnesium carbonate dusts in other marketable products may not be within the control of the
operator.
68.
In order to reduce/minimise process losses/waste, BAT is to reuse sludge resulting from the wet process of the flue-
gas desulphurisation in the process or in other sectors.

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L 100/40
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Official Journal of the European Union
9.4.2013
Applicability
The utilisation of sludge resulting from the wet process of the flue-gas desulphurisation in other sectors may not be
within the control of the operator.
1.4.6 Use of wastes as fuels and/or raw materials
69. In order to guarantee the characteristics of waste to be used as fuels and/or raw materials in magnesium oxide
kilns, BAT is to use the following techniques:
Technique
a To
select
suitable
wastes
for
the
process
and
the
burner
b
To apply quality assurance systems to guarantee and control the characteristics of wastes and to analyse any
waste that is to be used for:
I. availability
II. constant quality
III. physical criteria, e.g. emissions formation, coarseness, reactivity, burnability, calorific value
IV. chemical criteria, e.g. chlorine, sulphur, alkali and phosphate content and relevant metals (e.g. total
chromium, lead, cadmium, mercury, thallium) content
c
To control the amount of relevant parameters for any waste that is to be used, such as total halogen content,
metals (e.g. total chromium, lead, cadmium, mercury, thallium) and sulphur
Applicability
Wastes may be used as fuels and/or raw materials in the magnesia industry (although they had not yet been applied in the
magnesia industry in 2007) subject to availability, the type of kiln used, the desired product qualities and the technical
possibility of feeding the fuels into the kiln.
DESCRIPTION OF TECHNIQUES
1.5 Description of techniques for the cement industry
1.5.1 Dust emissions
Technique Description
a Electrostatic
precipitators Electrostatic
precipitators
(ESPs)
generate
an
electrostatic
field
across
the
path
of
particulate matter in the air stream. The particles become negatively charged and
migrate towards positively charged collection plates. The collection plates are rapped
or vibrated periodically, dislodging the material so that it falls into collection
hoppers below. It is important that ESP rapping cycles be optimised to minimise
particulate re-entrainment and thereby minimise the potential to affect plume
visibility.
ESPs are characterised by their ability to operate under conditions of high
temperatures (up to approximately 400 °C) and high humidity. The major
disadvantages of this technique are their decreased efficiency with an insulating
layer and a build-up of material that may be generated with high chlorine and
sulphur inputs. For the overall performance of ESPs, it is important to avoid CO
trips
Even though there are no technical restrictions on the applicability of ESPs in the
various processes in the cement industry, they are not often chosen for cement mill
dedusting because of the investment costs and the efficiency (relatively high
emissions) during start-ups and shutdowns
b Fabric
filters Fabric
filters
are
efficient
dust
collectors.
The
basic
principle
of
fabric
filtration
is
to
use a fabric membrane which is permeable to gas but which will retain the dust.
Basically, the filter medium is arranged geometrically. Initially, dust is deposited
both on the surface fibres and within the depth of the fabric, but as the surface
layer builds up, the dust itself becomes the dominating filter medium. Off-gas can
flow either from the inside of the bag outwards or vice versa. As the dust cake
thickens, the resistance to gas flow increases. Periodic cleaning of the filter medium
is therefore necessary to control the gas pressure drop across the filter. The fabric

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EN
9.4.2013 Official
Journal
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European
Union L
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Technique Description
filter should have multiple compartments which can be individually isolated in case
of bag failure and there should be sufficient of these to allow adequate performance
to be maintained if a compartment is taken off line. There should be ‘burst bag
detectors’ in each compartment to indicate the need for maintenance when this
happens. Filter bags are available in a range of woven and non-woven fabrics.
Modern synthetic fabrics can operate at quite high temperatures of up to 280 °C.
The performance of fabric filters is mainly influenced by different parameters, such
as compatibility of the filter medium with the characteristics of the flue-gas and the
dust, suitable properties for thermal, physical and chemical resistance, such as
hydrolysis, acid, alkali, and oxidation and process temperature. Moisture and
temperature of the flue-gases have to be taken into consideration during the
selection of the technique.
c Hybrid
filters Hybrid
filters
are
the
combination
of
ESPs
and
fabric
filters
in
the
same
device.
They
generally result from the conversion of existing ESPs. They allow the partial reuse of
the old equipment
1.5.2 NO x emissions
Technique Description
a Primary
measures/techniques
I Flame cooling
The addition of water to the fuel or directly to the flame by using different injection
methods, such as injection of one fluid (liquid) or two fluids (liquid and compressed
air or solids) or the use of liquid/solid wastes with a high water content reduces the
temperature and increases the concentration of hydroxyl radicals. This can have a
positive effect on NO x reduction in the burning zone
II Low NO x burners Designs
of
low
NO x burners (indirect firing) vary in detail but essentially the fuel
and air are injected into the kiln through concentric tubes. The primary air
proportion is reduced to some 6 – 10 % of that required for stoichiometric
combustion (typically 10 – 15 % in traditional burners). Axial air is injected at
high momentum in the outer channel. The coal may be blown through the
centre pipe or the middle channel. A third channel is used for swirl air, its swirl
being induced by vanes at, or behind, the outlet of the firing pipe. The net effect of
this burner design is to produce very early ignition, especially of the volatile
compounds in the fuel, in an oxygen-deficient atmosphere, and this will tend to
reduce the formation of NO x .
The application of low NO x burners is not always followed by a reduction of NO x
emissions. The set-up of the burner has to be optimised
III Mid kiln firing
In long wet and long dry kilns, the creation of a reducing zone by firing lump fuel
can reduce NO x emissions. As long kilns usually have no access to a temperature
zone of about 900 – 1 000 °C, mid-kiln firing systems can be installed in order to
be able to use waste fuels that cannot pass the main burner (for example tyres).
The rate of the burning of fuels can be critical. If it is too slow, reducing conditions
can occur in the burning zone, which may severely affect product quality. If it is too
high, the kiln chain section can be overheated – resulting in the chains being burned
out. A temperature range of less than 1 100 °C excludes the use of hazardous waste
with a chlorine content of greater than 1 %
IV Addition of miner The addition of mineralisers, such as fluorine, to the raw material is a technique to
alisers to improve the adjust the clinker quality and allow the sintering zone temperature to be reduced.
burnability of the By reducing/lowering the burning temperature, NO x formation is also reduced
raw meal (mineralised
clinker)

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L 100/42
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Official Journal of the European Union
9.4.2013
Technique Description
V Process optimisation
Optimisation of the process, such as smoothing and optimising the kiln operation
and firing conditions, optimising the kiln operation control and/or homogenisation
of the fuel feedings, can be applied for reducing NO x emissions. General primary
optimisation measures/techniques, such as process control measures/techniques, an
improved indirect firing technique, optimised cooler connections and fuel selection,
and optimised oxygen levels have been applied
b Staged
combustion
(con Staged combustion is applied at cement kilns with an especially designed precal
ventional or waste fuels), ciner. The first combustion stage takes place in the rotary kiln under optimum
also in combination with conditions for the clinker burning process. The second combustion stage is a
a precalciner and the use burner at the kiln inlet, which produces a reducing atmosphere that decomposes
of optimised fuel mix
a portion of the nitrogen oxides generated in the sintering zone. The high
temperature in this zone is particularly favourable for the reaction which reconverts
the NO x to elementary nitrogen. In the third combustion stage, the calcining fuel is
fed into the calciner with an amount of tertiary air, producing a reducing
atmosphere there, too. This system reduces the generation of NO x from the fuel,
and also decreases the NO x coming out of the kiln. In the fourth and final
combustion stage, the remaining tertiary air is fed into the system as ‘top air’ for
residual combustion
c SNCR Selective
non-catalytic
reduction
(SNCR)
involves
injecting
ammonia
water
(up
to
25 % NH 3 ), ammonia precursor compounds or urea solution into the combustion
gas to reduce NO to N 2 . The reaction has an optimum effect in a temperature
window of about 830 to 1 050 °C, and sufficient retention time must be provided
for the injected agents to react with NO
d SCR SCR
reduces
NO
and
NO 2 to N 2 with the help of NH 3 and a catalyst at a
temperature range of about 300 – 400 °C. This technique is widely used for NO x
abatement in other industries (coal fired power stations, waste incinerators). In the
cement industry, basically two systems are considered: low dust configuration
between a dedusting unit and stack, and a high dust configuration between a
preheater and a dedusting unit. Low dust flue-gas systems require the reheating
of the flue-gases after dedusting, which may cause additional energy costs and
pressure losses. High dust systems are considered preferable for technical and econ
omical reasons. These systems do not require reheating, because the waste gas
temperature at the outlet of the preheater system is usually in the right temperature
range for SCR operation
1.5.3 SO x emissions
Technique Description
a Absorbent
addition
Absorbent is either added to the raw materials (e.g. hydrated lime addition) or
injected into the gas stream (e.g. hydrated or slaked lime (Ca(OH) 2 ), quicklime
(CaO), activated fly ash with a high CaO content or sodium bicarbonate (NaHCO 3 )).
Hydrated lime can be charged into the raw mill together with the raw material
constituents or directly added to the kiln feed. The addition of hydrated lime offers
the advantage that the calcium-bearing additive forms reaction products that can be
directly incorporated into the clinker-burning process.
Absorbent injection into the gas stream can be applied in a dry or wet form (semi-
dry scrubbing). The absorbent is injected into the flue-gas path at temperatures close
to the water dew point, which results in more favourable conditions for SO 2
capture. In cement kiln systems, this temperature range is usually reached in the
area between the raw mill and the dust collector

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9.4.2013 Official
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European
Union L
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Technique Description
b Wet
scrubber The
wet
scrubber
is
the
most
commonly
used
technique
for
flue-gas
desulphuri
sation in coal-fired power plants. For cement manufacturing processes, the wet
process for reducing SO 2 emissions is an established technique. Wet scrubbing is
based on the following chemical reaction:
SO 2 + O 2 + 2 H 2 O + CaCO 3 ←→ CaSO 4 2 H 2 O + CO 2
SO x are absorbed by a liquid/slurry which is sprayed in a spray tower. The
absorbent is generally calcium carbonate. Wet scrubbing systems provide the
highest removal efficiencies for soluble acid gases of all flue-gas desulphurisation
(FGD) methods with the lowest excess stoichiometric factors and the lowest solid
waste production rate. The technique requires certain amounts of water with a
consequent need for waste water treatment
1.6 Description of techniques for lime industry
1.6.1 Dust emissions
Technique Description
a ESP A
general
description
of
ESPs
is
provided
in
Section
1.5.1.
ESPs are suitable for use at temperatures above the dew point and up to 400 °C.
Furthermore, it is also possible to use ESPs close to, or below, the dew point.
Because of high volume flows and relatively high dust loads, mainly rotary kilns
without preheaters but also rotary kilns with preheaters are equipped with ESPs. In
the case of combination with a quenching tower, excellent performance can be
achieved
b Fabric
filter A
general
description
of
fabric
filters
is
provided
in
Section
1.5.1.
Fabric filters are well suited for kilns, milling and grinding plants for quicklime as
well as for limestone; lime hydrating plants; material transport; and storage and
loading facilities. Often a combination with cyclone prefilters is useful. The
operation of fabric filters is limited by the flue-gas conditions such as temperature,
moisture, dust load and chemical composition. There are various fabric materials
available to resist mechanical, thermal and chemical wear to meet those conditions
c Wet
dust
separator
With wet dust separators, dust is eliminated from off-gas streams by bringing the
gas flow into close contact with a scrubbing liquid (usually water), so that the dust
particles are retained in the liquid and can be rinsed away. There are a number of
different types of wet scrubbers available for dust removal. The main types that have
been used in lime kilns are multi-cascade/multistage wet scrubbers, dynamic wet
scrubbers and venturi wet scrubbers. The majority of wet scrubbers used on lime
kilns are multi-cascade/multistage wet scrubbers.
Wet scrubbers are chosen when the flue-gas temperatures are close to, or below the
dew point. They may also be chosen when space is limited. Wet scrubbers are
sometimes used with higher temperature gases, in which case, the water cools the
gases and reduces their volume
d Centrifugal
Separator/ In a centrifugal separator/cyclone, the dust particles to be eliminated from an off-gas
cyclone
stream are forced out against the outer wall of the unit by centrifugal action and
then eliminated through an aperture at the bottom of the unit. Centrifugal forces
can be developed by directing the gas flow in a downward spiral motion through a
cylindrical vessel (cyclonic separators) or by a rotating impeller fitted in the unit
(mechanical centrifugal separators). However, they are only suitable as pre-separators
because of their limited particle removal efficiency and they relieve ESPs and fabric
filters from high dust loading, and reduce abrasion problems

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L 100/44
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Official Journal of the European Union
9.4.2013
1.6.2 NO x emissions
Technique Description
a Burner
design
(low
NO x The low NO x burners are useful for reducing the flame temperature and thus
burner)
reducing thermal and (to some extent) fuel derived NO x . The NO x reduction is
achieved by supplying rinsing air for lowering the flame temperature or pulsed
operation of the burners. Low NO x burners are designed to reduce the primary
air portion which leads to lower NO x formation whereas common multi-channel
burners are operated with a primary air portion of 10 to 18 % of the total
combustion air. The higher portion of the primary air leads to a short and
intensive flame by the early mixing of hot secondary air and fuel. This results in
high flame temperatures along with a creation of a high amount of NO x formation
which can be avoided by using low NO x burners
b Air
staging
A reducing zone is created by reducing the oxygen supply in the primary reaction
zones. High temperatures in this zone are particularly favourable for the reaction
which reconverts the NO x to elementary nitrogen. At later combustion zones, the
air and oxygen supply is increased to oxidise the gases formed. Effective air/gas
mixing in the firing zone is required to ensure that CO and NO x are both main
tained at low levels.
In 2007, air staging had never been applied in the lime sector
c SNCR Nitrogen
oxides
(NO
and
NO 2 ) from the flue-gases are removed by selective non-
catalytic reduction and converted into nitrogen and water by injecting a reducing
agent into the kiln which reacts with the nitrogen oxides. Ammonia or urea is
typically used as the reducing agent. The reactions occur at temperatures of between
850 and 1 020 °C, with the optimal range typically between 900 to 920 °C
1.6.3 SO x emissions
Technique Description
a Absorbent
addition
tech The technique involves the addition of an absorbent in dry form directly into the
niques
kiln (fed or injected) or in dry or wet form (e.g. hydrated lime or sodium bicar
bonate) into the flue-gases in order to remove SO x emissions. When absorbent is
injected into the flue-gases, a sufficient residence time between the injection point
and the dust collector (fabric filter or ESP) must be provided in order to obtain an
efficient absorption.
For rotary kilns, absorption techniques may include:
— Use of fine limestone: At a straight rotary kiln fed with dolomite, significant
reductions in SO 2 emissions can occur with feedstones which either contain
high levels of finely divided limestone or are prone to break up on heating. The
finely divided limestone calcines are entrained in the kiln gases and remove SO 2
en route to, and in, the dust collector.
— Lime injection into the combustion air: A patented technique (EP 0 734 755
A1) which removes SO 2 emissions from rotary kilns by injecting finely divided
quick or hydrated lime into the air fed into the firing hood of the kiln
1.7 Description of techniques for the magnesia industry (dry process route)
1.7.1 Dust emissions
Measure/Technique Description
a Electrostatic
precipitators
A general description of ESPs is provided in Section 1.5.1
(ESPs)

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9.4.2013 Official
Journal
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European
Union L
100/45
Measure/Technique Description
b Fabric
filters A
general
description
of
fabric
filters
is
provided
in
Section
1.5.1
Fabric filters receive high particle retention, typically over 98 % and up to 99 %
depending on the particle size. This technique offers the best efficiency on particle
collection in comparison to other dust abatement measures/techniques used in the
magnesia industry. However, because of the high temperatures of the kiln flue-gases,
special filter materials which can tolerate high temperatures have to be used.
In DBM manufacturing, filter materials operating with temperatures of up to 250 °C
are used, such as PTFE (Teflon) filter material. This filter material shows good
resistance to acids or alkalis and a lot of corrosion problems have been solved
c Cyclones
(centrifugal A general description of cyclones is provided in Section 1.6.1. They are robust
separator)
equipment and they have a wide operational temperature range with a low
energy requirement. Because of the system-dependent limited degree of separation,
cyclones are mainly used as preliminary separators for coarse dust and flue-gases
d Wet
dust
separators
General description of wet dust separators (also called wet scrubbers) is provided in
Section 1.6.1
Wet dust separators can be divided into various types according to their design and
working principles, such as the venturi type. This type of wet dust separator has a
number of applications in the magnesia industry, including when gas is directed
through the narrowest section of the venturi tube, the ‘venturi neck’, and gas
velocities of between 60 and 120 m/s can be achieved. The washing fluids which
are fed into the venturi tube neck are diffused into a mist of very fine droplets and
are intensively mixed with the gas. The particles separated onto the water droplets
become heavier and can be readily drawn off using a drop separator installed in this
venturi wet dust separator
1.7.2 SO x emissions
Technique Description
a Absorbent
addition
tech The technique involves the injection of an absorbent in dry or wet form (semi-dry
nique
scrubbing) into the flue-gases in order to remove SO x emissions. A sufficient gas
residence time between the injection point and the dust collector is very important
to obtain highly efficient absorption. Reactive MgO grades can be used as efficient
absorbents for SO 2 in the magnesia industry. Despite the lower efficiency compared
to other absorbents, the use or reactive MgO grades has a double advantage as it
lowers the investment costs and also the filter dust is not contaminated by other
substances and can be reused in place of raw materials for the production of
magnesia or employed as a fertiliser (magnesium sulphate) minimising waste gener
ation
b Wet
scrubber In
the
wet
scrubbing
technique,
SO x are absorbed by a liquid/slurry which is sprayed
countercurrently to the flue-gases in a spray tower. The technique requires an
amount of water between 5 and 12 m 3 /tonne product, with a consequent need
for a waste water treatment

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Document Outline

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